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:

Self-Diagnosis Outline
The self-diagnosis system is monitoring the following mechanisms. DFI System and Ignition System S-KTRC System Immobilizer System (Equipped Models) KIBS and ABS (Equipped Models) ESD (Electronic Steering Damper) System (ZX1000JD/KD) The following warning indicator lights (LED) are used for ...

Drive Chain Removal/Installation
NOTE Since the drive chain is installed through the swingarm, The chain can not be removed other than by cutting it. Prepare the new link pin, link plate, grease seals, and tools for rejoining the chain. Remove: Bolts [A] Front Footpeg Bracket [B] Remove: Bolts [A] Chain Cover [B] ...

Brake Light Switch Operation Inspection
Turn the ignition switch to ON. The brake light (LED) [A] should go on when the brake lever is applied or after the brake pedal is depressed about 10 mm (0.39 in.). If it does not, adjust the brake light switch. Remove the front footpeg bracket (see Brake Pedal Removal in the B ...