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:

Intake Air Temperature Sensor Resistance Inspection
Remove the intake air temperature sensor (see Intake Air Temperature Sensor Removal). Suspend the sensor [A] in a container of machine oil so that the heat-sensitive portion is submerged. Suspend a thermometer [B] with the heat-sensitive portion [C] located in almost the same depth with ...

Starter Clutch Installation
Replace the O-ring [A] with a new one and apply grease. Apply molybdenum disulfide grease to the starter clutch shaft [B]. Install: Starter Clutch [C] Spacer (Small Diameter) [D] Spacer (Large Diameter) [E] Starter Clutch Shaft Starter Clutch Shaft Holder [F] Turn the O-ring si ...

Brake Fluid Leak (Brake Hose and Pipe) Inspection
For KIBS equipped models, remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses [A], pipes (KIBS equipped models) [B] and fittings [C]. If the brake fluid leaked from any posit ...