Kawasaki Ninja Service Manual: Spring Plate Free Play Adjustment

Kawasaki Ninja Service Manual / Clutch / Clutch / Spring Plate Free Play Adjustment

NOTE

The free play adjustment is performed by replacing the steel plate(s).

Measure the clutch spring plate free play (see Clutch Spring Plate Free Play Measurement), and then replace the steel plate(s) which brings the free play within the usable range.

Spring Plate Free Play Usable Range: 0.05 0.70 mm (0.002
0.028 in.)

Replace the following steel plate(s).

NOTE

Do not use the steel plate of 2.3 mm (0.090 in.) and 2.9 mm (0.114 in.) thickness at the same time.

Clutch Plate Assembly Length (Reference Information)

Assemble the following parts.

Clutch Hub [A] Spring Seat [B] Spring [C] Sub Clutch Hub [D] Sub Clutch Hub Bolts [E] New Friction Plates [F] Steel Plates [G] Spring Plate [H] Clutch Springs [I] Clutch Spring Holders [J] Clutch Spring Bolts [K]

Torque - Clutch Spring Bolts: 11 N·m (1.1 kgf·m, 97 in·lb)

Measure the clutch plate assembly length [L].

Clutch Plate Assembly Length (Reference) 53.5 mm (2.11 in.)

Clutch Plate Assembly Length (Reference Information)

NOTE

The length of the clutch plate assembly changes by the steel plate thickness.

Spring Plate Free Play Measurement

Insufficient clutch free play will cause the engine braking effect to be more sudden, resulting in rear wheel hop. On the other hand, if the free play is excessive, the clutch lever may feel “spo ...

Clutch Plate, Wear, Damage Inspection

Visually inspect the friction and steel plates for signs of seizure, overheating (discoloration), or uneven wear. Measure the thickness of each friction plate [A] at several points. If any ...

Other materials:

Warning Symbols
: The red warning indicator light and the oil pressure warning symbol ( ) goes on whenever the oil pressure is dangerously low or the ignition switch is in the “ON” position with the engine not running, and go off when the engine oil pressure is high enough. Refer to the Mainten ...

Crankshaft Sensor Removal
Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Crankshaft Sensor Lead Connector [A] Remove: Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Bolts [A] Crankshaft Sensor Cover [B] and Gasket Oil Pressure Switch Terminal [C] ...

Exhaust Butterfly Valve Actuator Sensor Input Voltage Inspection
NOTE Be sure the battery is fully charged. Turn the ignition switch to OFF. Remove the front seat (see Front Seat Removal in the Frame chapter). Remove the screws [A] and the exhaust butterfly valve actuator temporarily with the cables installed. Disconnect the exhaust butterf ...