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:

Rear Fender Front Removal
Remove: Flap and Rear Fender Rear (see Flap and Rear Fender Rear Removal) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Battery (see Battery Removal in the Electrical System chapter) Exhaust Butterfly Valve Actuator (see Exhaust Butterfly Valve Actuator Remova ...

Starter Motor Assembly
Install the positive brush assy [A] and the starter motor terminal [B] as shown in the figure. Replace the O-ring [C] with a new one, and install it. Install: Brush Springs [A] Negative Brush Assy [B] Turn the stopper side [C] to inside. Tighten: Torque - Brush Holder S ...

Throttle Body Assy Assembly
Before assembling, blow away dirt or dust from the throttle body and delivery pipe assy by applying compressed air. Replace the O-rings [A] of the joint pipe [B] with new ones. Apply engine oil to the new O-rings, and insert it to the delivery pipes [C]. Insert the joint pipe so th ...