Kawasaki Ninja Service Manual: Clutch

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

Clutch Operation Inspection

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.

Clutch Operation Inspection


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

60В° [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


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:

Piston Ring Groove Width Inspection
Measure the piston ring groove width. Use a vernier caliper at several points around the piston. Piston Ring Groove Width Standard: Top [A] 0.82 0.84 mm (0.0323 0.0331 in.) Second [B] 0.82 0.84 mm (0.0323 0.0331 in.) Service Limit: 0.92 mm (0.036 in.) Second 0.92 mm (0.036 in.) ...

Spring Preload Adjustment
Remove the rear shock absorber from the frame (see Rear Shock Absorber Removal). Loosen the locknut and turn out the adjusting nut to free the spring. Special Tools - Hook Wrench T=3.2 R37: 57001-1539 Hook Wrench R=35: 57001-1580 To adjust the spring preload, turn in the adjusting n ...

Oil Pump Installation
Install the outer rotor [A] into the crankcase. Assemble: Oil (Water) Pump Shaft [B] Pin [C] Inner Rotor [D] To prevent dropping, apply grease to the pin. Install the inner rotor assembly into the crankcase. Fit the slot [E] onto the projection [F]. Replace the O-ring [A ...