Kawasaki Ninja Service Manual: Starter Clutch Installation
- Replace the O-ring [A] with a new one and apply grease.
- Apply molybdenum disulfide grease to the starter clutch
shaft [B].
- Install:
Starter Clutch [C]
Spacer (Small Diameter) [D]
Spacer (Large Diameter) [E]
Starter Clutch Shaft
Starter Clutch Shaft Holder [F]
Turn the O-ring side of the shaft to outside as shown in
the figure.
- Apply a non-permanent locking agent to the starter clutch
shaft bolt [G] and the starter clutch shaft holder bolt [H].
- Tighten:
Torque - Starter Clutch Shaft Holder Bolt: 9.8 N·m (1.0
kgf·m, 87 in·lb)
Starter Clutch Shaft Bolt: 20 N·m (2.0 kgf·m, 15
ft·lb)
- Install the removed parts (see appropriate chapters).
Remove:
Torque Limiter (see Torque Limiter Removal)
Transmission Assy (see Transmission Assy Removal)
Starter Clutch Shaft Holder Bolt [A]
Starter Clutch Shaft Bolt [B]
Starter Clutch Sha ...
Remove the starter clutch (see Starter Clutch Removal).
Take the drive gear [A] off the driven gear [B].
Remove the needle bearing [C].
Remove the snap ring [D].
Take the one-way clutch [E] ...
Other materials:
Cylinder Compression Measurement
NOTE
Use the battery which is fully charged.
Warm up the engine thoroughly.
Stop the engine.
Remove the spark plugs (see Spark Plug Replacement in
the Periodic Maintenance chapter).
Attach the compression gauge [A] and adapter [B] firmly
into the spark plug hole.
Using the startermo ...
Connecting Rod Big End Side Clearance Inspection
Measure connecting rod big end side clearance.
Insert a thickness gauge [A] between the big end and either
crank web to determine clearance.
Connecting Rod Big End Side Clearance
Standard: 0.13 0.38 mm
(0.0051 0.0150 in.)
Service Limit: 0.58 mm (0.023 in.)
If the clearance exceeds ...
Wiring Diagram (Other than US, CA and CAL with KIBS Models)
ZX1000KC
ZX1000KD
...
Starter Clutch Removal
Starter Clutch Disassembly