Kawasaki Ninja Service Manual: Spring Plate Free Play Measurement

Kawasaki Ninja Service Manual / Clutch / Clutch / 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 “spongy” or pulsate when pulled.

Hold an extra drive shaft in a vise and install the following clutch parts on the shaft (see Clutch Installation).

Collar [A] Needle Bearing [B] Sleeve [C] Clutch Housing [D] Spacer [E] Clutch Hub [F] Sub Clutch Hub [G] Friction Plates (48 Lining Blocks) [H] (#1, #10) Steel Plates (T = 2.9) [I] (#1
#7) Spring Seat [J] Spring [K] Friction Plates (36 Lining Blocks) [L] (#2 #9)
Steel Plates (T = 2.6) [M] (#8, #9) Clutch Spring Plate [N]

Spring Plate Free Play Measurement

Engage the clutch hub with the sub clutch hub.
To measure the free play, set a dial gauge [A] against the raised center [B] of the clutch spring plate.
Move the clutch housing gear back and forth [C]. The difference between the highest and lowest gauge readings is the amount of free play.

Drive Shaft [D]
Measure the spring plate free play.

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

Spring Plate Free Play Measurement

If the free play is not within the usable range, change all of the friction plate and measure the free play again.

If the free play is not within the usable range, adjust the free play (see Spring Plate Free Play Adjustment).

Clutch Installation

Apply engine oil to the needle bearing [A] and the sleeve [B]. Install: Needle Bearing Sleeve Install the clutch housing [A]. Fit the holes [B] and projections [C]. Engage the ...

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 st ...

Other materials:

Engine Installation
Apply molybdenum disulfide grease to the threads of the adjusting collars [A]. Install the adjusting collars to crankcase backside until end of the threads. Install the adjusting collar [A] to the frame until end of the threads. Replace the engine mounting nuts with ne ...

Fuel Hose Inspection (fuel leak, damage, installation condition)
If the motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak [A] or the hose to burst. Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) and check the fuel hoses. Replace the fuel hose if any fraying, cracks [B] or ...

Torque Limiter Removal
Remove: Starter Motor (see Starter Motor Removal in the Electrical System chapter) Throttle Body Assy Holder [A] Breather Hose [B] Roll up the heat insulation rubber plate [C]. Remove: Torque Limiter Cover Bolts [A] Torque Limiter Cover [B] Remove: Torque Limit ...