Kawasaki Ninja Service Manual: Clutch Spring Free Length Measurement

Kawasaki Ninja Service Manual / Clutch / Clutch / Clutch Spring Free Length Measurement

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: 42.1 mm (1.66 in.)

Clutch Spring Free Length Measurement


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 ...

Clutch Housing Finger Inspection
Visually inspect the clutch housing fingers [A] where the friction plate tangs [B] hit them. If they are badly worn or if there are groove cuts where the tangs hit, replace the housing. Also, ...

Other materials:

Stem, Stem Bearing Installation
Replace the bearing outer races with new ones. Drive them into the head pipe at the same time. Special Tools - Head Pipe Outer Race Press Shaft [A]: 57001-1075 Head Pipe Outer Race Driver, 55 [B]: 57001 -1446 or Bearing Driver Set: 57001-1129 Apply grease to the outer races. ...

Timing Rotor Installation
Install the timing rotor [A] on the crankshaft [B] with their teeth [C] aligned. Holding the timing rotor with the flywheel & pulley holder and tighten the bolt. Torque - Timing Rotor Bolt: 39 N·m (4.0 kgf·m, 29 ft·lb) Special Tool - Flywheel & Pulley Holder: 57001-1605 I ...

Air Suction Valve Inspection
Remove the air suction valve (see Air Suction Valve Removal). Visually inspect the reeds [A] for cracks, folds, warps, heat damage or other damage. If there is any doubt as to the condition of the reeds, replace the air suction valve as an assembly. Check the reed contact areas [B] of ...