Kawasaki Ninja Service Manual: Clutch Cover Installation

Kawasaki Ninja Service Manual / Clutch / Clutch Cover / Clutch Cover Installation

Using a cleaning fluid, clean off any oil or dirt that may be on the silicone sealant coating area. Dry them with a clean cloth.
Apply silicone sealant to the area [A] where the mating surface of the crankcase touches the clutch cover gasket.

Sealant - Liquid Gasket, TB1211F: 92104-0004

Clutch Cover Installation

Be sure that the dowel pins [B] are in position.
Replace the clutch cover gasket with a new one.

Clutch Cover Installation

Tighten the clutch cover bolts by following the sequence numbers [1 15].

Torque - Clutch Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

Tighten the bolt (L = 45 mm, 1.8 in.) [A] together with the clutch cable bracket [B] as shown in the figure.

Clutch Cover Installation

Clutch Cover Removal

Remove: Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Clutch Cable Lower End (see Cable Removal) Clutch Cover Bolts [A] Turn the release lever [A] countercl ...

Release Shaft Removal

NOTICE Do not remove the clutch release lever and shaft assembly unless it is absolutely necessary. If removed, the oil seal replacement may be required. Remove the clutch cover (see Clutch ...

Other materials:

Air Cleaner Housing Installation
For ZX1000JD/KD, be sure to install the pad [A]. Install the clamp bolt heads [A] inside as shown in the figure. Install the air cleaner housing on the throttle body assy. Push in the ducts [B] touch the stoppers [C] of the throttle body. Be sure the hoses are routed correctly ...

Lights and Switches Operation Inspection
First Step Set the gear position in the neutral position. Turn the ignition switch to ON. The following lights should go on according to below table. If the following light does not go on, inspect the meter unit (see Meter Unit Inspection in the Electrical System chapter). ...

Brake Line Bleeding
The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action. Air, however, is easily compressed. When air enters the brake lines, brake lever or pedal movement will be partially used ...