Kawasaki Ninja Service Manual: Clutch Cover Installation

Kawasaki Ninja Service Manual / Clutch / Clutch Cover / Clutch Cover Installation

Using a cleaning fluid, clean off any oil or dirt that may be on the silicone sealant coating area. Dry them with a clean cloth.
Apply silicone sealant to the area [A] where the mating surface of the crankcase touches the clutch cover gasket.

Sealant - Liquid Gasket, TB1211F: 92104-0004

Clutch Cover Installation

Be sure that the dowel pins [B] are in position.
Replace the clutch cover gasket with a new one.

Clutch Cover Installation

Tighten the clutch cover bolts by following the sequence numbers [1 15].

Torque - Clutch Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

Tighten the bolt (L = 45 mm, 1.8 in.) [A] together with the clutch cable bracket [B] as shown in the figure.

Clutch Cover Installation

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] countercl ...

Release Shaft Removal

NOTICE Do not remove the clutch release lever and shaft assembly unless it is absolutely necessary. If removed, the oil seal replacement may be required. Remove the clutch cover (see Clutch ...

Other materials:

Rear Sprocket Warp Inspection
Raise the rear wheel off the ground with the stand so that it will turn freely. Set a dial gauge [A] against the rear sprocket [B] near the teeth as shown in the figure, and rotate [C] the rear wheel to measure the sprocket runout (warp). The difference between the highest and lowest di ...

Fuel Tank Removal
WARNINGGasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. T ...

Front Wheel Rotation Sensor Signal Abnormal (Service Code b 42)
Measure the air gap between the front wheel rotation sensor and sensor rotor. Thickness Gauge [A] Air Gap Standard: 0.4 1.6 mm (0.02 0.06 in.) If the measurement is not the standard, check each part for deformation and looseness and correct accordingly. If the measurement is t ...