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:

Ball Bearing and Needle Bearing
Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown. Pressing the incorrect ra ...

ECU Removal
NOTICE Never drop the ECU especially on a hard surface. Such a shock to the ECU can damage it. Remove the upper air cleaner housing (see Air Cleaner Element Replacement in the Periodic Maintenance chapter). Lift up the ECU [A] with rubber protector [B] to disconnect the connectors [C]. ...

Idle Speed Control Valve Actuator Removal
NOTICE Never drop the idle speed control valve actuator especially on a hard surface. Such a shock to the actuator can damage it. Remove: Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Idle Speed Control Valve Actuator Retainer Screws [A] Idle Spe ...