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

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Other materials:

For Secondary Fuel Injectors
Remove the fuel tank (see Fuel Tank Removal). Disconnect the secondary fuel injector connector [A]. Connect a digitalmeter to the terminals in each secondary fuel injector [A]. Measure the secondary fuel injector resistance. Secondary Fuel Injector Resistance Standard: Abo ...

Front Fork Inspection
Holding the brake lever, pump the front fork up and down several times to inspect smooth stroke. Visually inspect the front fork for oil leakage, scoring or scratches on the outer surface of the inner tube. If any doubt about the front fork, it should be checked by an authorized K ...

Coolant Level Inspection
NOTE Check the level when the engine is cold (room or ambient temperature). Check the coolant level in the reserve tank [A] with the motorcycle held perpendicular (Do not use the sidestand). If the coolant level is lower than the “L” level line [B], remove the upper fairing assembly (s ...