Kawasaki Ninja Service Manual: Spring Plate Free Play Adjustment

Kawasaki Ninja Service Manual / Clutch / Clutch / Spring Plate Free Play Adjustment

NOTE

The free play adjustment is performed by replacing the steel plate(s).

Measure the clutch spring plate free play (see Clutch Spring Plate Free Play Measurement), and then replace the steel plate(s) which brings the free play within the usable range.

Spring Plate Free Play Usable Range: 0.05 0.70 mm (0.002
0.028 in.)

Replace the following steel plate(s).

NOTE

Do not use the steel plate of 2.3 mm (0.090 in.) and 2.9 mm (0.114 in.) thickness at the same time.

Clutch Plate Assembly Length (Reference Information)

Assemble the following parts.

Clutch Hub [A] Spring Seat [B] Spring [C] Sub Clutch Hub [D] Sub Clutch Hub Bolts [E] New Friction Plates [F] Steel Plates [G] Spring Plate [H] Clutch Springs [I] Clutch Spring Holders [J] Clutch Spring Bolts [K]

Torque - Clutch Spring Bolts: 11 N·m (1.1 kgf·m, 97 in·lb)

Measure the clutch plate assembly length [L].

Clutch Plate Assembly Length (Reference) 53.5 mm (2.11 in.)

Clutch Plate Assembly Length (Reference Information)

NOTE

The length of the clutch plate assembly changes by the steel plate thickness.

Spring Plate Free Play Measurement

Insufficient clutch free play will cause the engine braking effect to be more sudden, resulting in rear wheel hop. On the other hand, if the free play is excessive, the clutch lever may feel “spo ...

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 ...

Other materials:

Swingarm Bearing, Sleeve Inspection
NOTICE Do not remove the bearings for inspection. Removal may damage them. Inspect the needle bearings [A] and ball bearing installed in the swingarm. The rollers and ball in a bearing normally wear very little, and wear is difficult to measure. Instead of measuring, visually inspec ...

Exhaust Butterfly Valve Actuator Sensor Resistance Inspection
Turn the ignition switch to OFF. Disconnect the exhaust butterfly valve actuator sensor connector (3 pins connector) [A] (see Exhaust Butterfly Valve Actuator Sensor Input Voltage Inspection). Connect a digital meter [B] to the exhaust butterfly valve actuator sensor connector. Measur ...

Thermostat Installation
Replace the O-rings [A] with new ones, and apply grease to them. Assemble: O-rings Thermostat Housing [B] Thermostat [C] Thermostat Cap [D] Install the thermostat [A] in the housing so that the air bleeder hole [B] is on top. Tighten: Torque - Thermostat Cap Bolts: 5.9 N ...