Kawasaki Ninja Service Manual: Clutch

Kawasaki Ninja Service Manual / Periodic Maintenance / Periodic Maintenance Procedures / Clutch

Clutch Operation Inspection

Pull the clutch lever just enough to take up the free play [A].
Measure the gap between the lever and the lever holder.

If the gap is too wide, the clutch may not release fully. If the gap is too narrow, the clutch may not engage fully. In either case, adjust it.

Clutch Lever Free Play Standard: 2 3 mm (0.08
0.12 in.)

Clutch Operation Inspection

WARNING

The engine and exhaust system get extremely hot during normal operation and can cause serious burns. Never touch the engine or exhaust pipe during clutch adjustment.

Turn the adjuster [A] so that 4 6 mm (0.16
0.24 in.) [B]
of threads is visible.

Clutch Operation Inspection

Loosen both adjusting nuts [A] at the bracket [B] on the clutch cover as far as they will go.
Pull the clutch outer cable [C] tight and tighten the adjusting nuts against the bracket.
Turn the adjuster at the clutch lever until the free play is correct.
Push the release lever [A] toward the front of the motorcycle until it becomes hard to turn.

At this time, the release lever should have the proper angle shown.

60° [B]

If the angle is wrong, check the clutch and release parts for wear.

WARNING

Too much cable play can prevent clutch disengagement and cause an accident resulting in serious injury or death. When adjusting the clutch or replacing the cable, be sure the upper end of the clutch outer cable is fully seated in its fitting, or it could slip into place later, creating enough cable play to prevent clutch disengagement.

Clutch Operation Inspection

After the adjustment, start the engine and check that the clutch does not slip and that it releases properly.

Air Suction System Damage Inspection

Separate the air switching valve hose [A] from the lower air cleaner housing [B] (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter). Connect the following parts tempor ...

Wheels/Tires

...

Other materials:

KIBS Troubleshooting Outline
When an abnormality in the system occurs, the ABS indicator light (LED) and KIBS indicator light (LED) light up and the KIBS warning symbol are displayed on the LCD (Liquid Crystal Display) to alert the rider. In addition, the nature of the fault is stored in the memory of the KIBS hydraulic uni ...

Clutch Cover Removal
Remove: Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Clutch Cable Lower End (see Cable Removal) Clutch Cover Bolts [A] Turn the release lever [A] counterclockwise as shown, and remove the clutch cover. About 90° [B] ...

Break-in
The first 1 600 km (1 000 mi) that the motorcycle is ridden is designated as the break-in period. If the motorcycle is not used carefully during this period, you may very well end up with a “broken down” instead of a “broken in” motorcycle after a few thousand kilometers. The fol ...