Kawasaki Ninja Owners Manual: Clutch

Kawasaki Ninja Owners Manual / Maintenance and adjustment / Clutch

Due to friction plate wear and clutch cable stretch over a long period of use, the clutch operation should be checked each day before riding the motorcycle, and must be adjusted in accordance with the Periodic Maintenance Chart.

Inspection

Check that the clutch lever operates properly and that the inner cable slides smoothly. If there is any irregularity, have the clutch cable checked by an authorized Kawasaki dealer.
Check the clutch lever play as shown in the figure.

A. Adjuster

B. Clutch Lever Play

Clutch Lever Play

If the play is incorrect, adjust the lever play as follows.

Adjustment

Turn the adjuster so that the clutch lever will have the proper play.

WARNING

Excess clutch cable play could prevent clutch disengagement and cause a crash resulting in serious injury or death. When adjusting the clutch cable, be sure the upper end of the outer cable is fully seated in its fitting so that it doesn’t slip into place later and create excessive cable play.

If it cannot be done, have the clutch cable adjusted by an authorized Kawasaki dealer.

WARNING

The engine and exhaust system get extremely hot during normal operation and can cause serious burns. Never touch a hot engine or an exhaust pipe during clutch adjustment.

NOTE

After the adjustment is made, start the engine and check that the clutch does not slip and releases properly.
For minor corrections, use the adjuster at the clutch lever.

DANGER

Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Inhaling carbon monoxide can cause serious brain injury or death.

DO NOT run the engine in enclosed areas. Operate only in a well-ventilated area.

Idle Speed

The idle speed inspection should be performed in accordance with the Periodic Maintenance Chart. This motorcycle is equipped with the Idle Speed Control valve. If the idle speed is disturbed, i ...

Drive Chain

The drive chain slack and lubrication must be checked each day before riding the motorcycle and must be maintained in accordance with the Periodic Maintenance Chart for safety and to prevent exce ...

Other materials:

Front Wheel Rotation Sensor Signal Abnormal (Service Code b 42)
Measure the air gap between the front wheel rotation sensor and sensor rotor. Thickness Gauge [A] Air Gap Standard: 0.4 1.6 mm (0.02 0.06 in.) If the measurement is not the standard, check each part for deformation and looseness and correct accordingly. If the measurement is t ...

Starter Clutch Installation
Replace the O-ring [A] with a new one and apply grease. Apply molybdenum disulfide grease to the starter clutch shaft [B]. Install: Starter Clutch [C] Spacer (Small Diameter) [D] Spacer (Large Diameter) [E] Starter Clutch Shaft Starter Clutch Shaft Holder [F] Turn the O-ring si ...

Brake Disc Installation
Install the brake disc on the wheel so that the marked side [A] faces out. Front Brake Discs [B] Rear Brake Disc [C] Apply a non-permanent locking agent to the threads of the brake disc mounting bolts. Tighten: Torque - Brake Disc Mounting Bolts: 27 N·m (2.8 kgf·m, 20 ...