Kawasaki Ninja Service Manual: Spring Plate Free Play Measurement

Kawasaki Ninja Service Manual / Clutch / Clutch / 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 “spongy” or pulsate when pulled.

Hold an extra drive shaft in a vise and install the following clutch parts on the shaft (see Clutch Installation).

Collar [A] Needle Bearing [B] Sleeve [C] Clutch Housing [D] Spacer [E] Clutch Hub [F] Sub Clutch Hub [G] Friction Plates (48 Lining Blocks) [H] (#1, #10) Steel Plates (T = 2.9) [I] (#1
#7) Spring Seat [J] Spring [K] Friction Plates (36 Lining Blocks) [L] (#2 #9)
Steel Plates (T = 2.6) [M] (#8, #9) Clutch Spring Plate [N]

Spring Plate Free Play Measurement

Engage the clutch hub with the sub clutch hub.
To measure the free play, set a dial gauge [A] against the raised center [B] of the clutch spring plate.
Move the clutch housing gear back and forth [C]. The difference between the highest and lowest gauge readings is the amount of free play.

Drive Shaft [D]
Measure the spring plate free play.

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

Spring Plate Free Play Measurement

If the free play is not within the usable range, change all of the friction plate and measure the free play again.

If the free play is not within the usable range, adjust the free play (see Spring Plate Free Play Adjustment).

Clutch Installation

Apply engine oil to the needle bearing [A] and the sleeve [B]. Install: Needle Bearing Sleeve Install the clutch housing [A]. Fit the holes [B] and projections [C]. Engage the ...

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 st ...

Other materials:

Cable, Wire, and Hose Routing
1. Clamp (Hold the regulator/rectifier lead. Run the lead inside of the installation hole.) 2. Clamp (Bend down the clamp, and hold the main harness and the vacuum hose (equipped models).) 3. Clamp (Hold the air intake solenoid valve lead (equipped models).) 4. Run the vacuum hose under ...

Wheel Bearing Damage Inspection
Raise the front wheel off the ground with the jack (see Front Wheel Removal in the Wheels/Tires chapter). Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 Turn the handlebar all the way to the right or left. Inspect the roughness of the front wheel bearing by moving [A] ...

Subthrottle Valve Actuator Input Voltage Inspection
NOTE Be sure the battery is fully charged. Turn the ignition switch to OFF. Disconnect the subthrottle valve actuator connector and connect the measuring adapter [A] between these connectors as shown in the figure. Main Harness [B] Subthrottle Valve Actuator [C] Special Tool ...