Kawasaki Ninja Service Manual: Clutch Plate Warp Inspection

Kawasaki Ninja Service Manual / Clutch / Clutch / Clutch Plate Warp Inspection

Place each friction plate or steel plate on a surface plate and measure the gap between the surface plate [A] and each friction plate or steel plate [B] with a thickness gauge [C]. The gap is the amount of friction or steel plate warp.

If any plate is warped over the service limit, replace it with a new one.

Clutch Plate Warp Inspection

Friction and Steel Plate Warp

Standard: 0.15 mm (0.0059 in.) or less

Service Limit: 0.3 mm (0.012 in.)

Clutch Plate, Wear, Damage Inspection

Visually inspect the friction and steel plates for signs of seizure, overheating (discoloration), or uneven wear. Measure the thickness of each friction plate [A] at several points. If any ...

Clutch Spring Free Length Measurement

Measure the free length of the clutch springs [A]. If any spring is shorter than the service limit, it must be replaced. Clutch Spring Free Length Standard: 43.5 mm (1.71 in.) Service Limit: ...

Other materials:

Commutator Cleaning and Inspection
Clean the metallic debris off the between commutator segments [A]. NOTE Do not use emery or sand paper on the commutator. Check the commutator for damage or abnormal wear. Replace the starter motor with a new one if there is any damage or wear. Visually inspect the commutato ...

Radiator Cap Inspection
Remove: Radiator Cap (see Coolant Change in the Periodic Maintenance chapter) Check the condition of the bottom [A] and top [B] valve seals and valve spring [C]. If any one of them shows visible damage, replace the cap with a new one. Install the cap [A] on a cooling system pr ...

Engine Installation
Apply molybdenum disulfide grease to the threads of the adjusting collars [A]. Install the adjusting collars to crankcase backside until end of the threads. Install the adjusting collar [A] to the frame until end of the threads. Replace the engine mounting nuts with ne ...