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:

Exploded View
13. Front Wheel Rotation Sensor B: Apply brake fluid. L: Apply a non-permanent locking agent. R: Replacement Parts S: Follow the specified tightening sequence. Si: Apply silicone grease (ex. PBC grease). 10. Rear Wheel Rotation Sensor B: Apply brake fluid. G: Apply gr ...

Commutator Cleaning and Inspection
Clean the metallic debris off the between commutator segments [A]. NOTE Do not use emery or sand paper on the commutator. Check the commutator for damage or abnormal wear. Replace the starter motor with a new one if there is any damage or wear. Visually inspect the commutato ...

Relay Circuit Inspection
Remove the relay box (see Relay Box Removal). Check conductivity of the following numbered terminals by connecting the hand tester and one 12 V battery to the relay box as shown in the figure (see Relay Box Internal Circuit in this section). If the tester does not read as specified, re ...