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 ...

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Turn Signal Switch
When the turn signal switch is pushed to the left ( ) or right ( ), the corresponding turn signals blink on and off. To stop blinking, push the switch in. Horn Button When the horn button is pushed, the horn sounds LAP/Passing Button When the LAP/passing button is pushed, the headlight hi ...

Special Tools
Bearing Driver Set: 57001-1129 Jack: 57001-1238 Bearing Remover Head, 25 × 28: 57001-1346 Bearing Remover Shaft, 13: 57001-1377 Jack Attachment: 57001-1608 ...

Piston Removal
Remove: Crankshaft (see Crankshaft Removal) Remove the piston together with the connecting rod to the cylinder head side. NOTICE Discard the connecting rod bolts and nuts. To prevent damage to the crankpin surfaces, do not allow the connecting rod bolts to bump against the crankpins. ...