Kawasaki Ninja Service Manual: Clutch Plate, Wear, Damage Inspection

Kawasaki Ninja Service Manual / Clutch / Clutch / 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 plates show signs of damage, or if they have worn past the service limit, replace them with new ones.

Clutch Plate, Wear, Damage Inspection

Friction Plate Thickness

Standard: 2.72 2.88 mm
(0.107 0.113 in.)

Service Limit: 2.5 mm (0.098 in.)

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 ...

Clutch Plate Warp Inspection

Place each friction plate or steel plate on a surface plate and measure the gap between the surface plate [A] and each friction plate or steel plate [B] with a thickness gauge [C]. The gap is ...

Other materials:

Shift Fork Guide Pin/Drum Groove Wear Inspection
Measure the diameter of each shift fork guide pin [A], and measure the width [B] of each shift drum groove. If the guide pin on any shift fork is less than the service limit, the fork must be replaced. Shift Fork Guide Pin Diameter Standard: 6.9 7.0 mm (0.272 0.276 in.) Service Limit: ...

Starting the Engine
Check that the engine stop switch is in the position. A. Engine Stop Switch B. Starter Button Turn the ignition key to “ON”. Make sure the transmission is in neutral. A. Neutral Indicator Light B. Ignition Switch C. “ON” position NOTE The motorcycle is equipped w ...

Subthrottle Valve Actuator Inspection
NOTE Be sure the battery is fully charged. Remove the air cleaner housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter). Turn the ignition switch to ON. Check to see that all the subthrottle valves [A] open and close smoothly. Turn the ignition switch to OFF. I ...