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:

Crankcase Assembly
NOTICE The upper and lower crankcase halves are machined at the factory in the assembled state, so the crankcase halves must be replaced as a set. With a high flash-point solvent, clean off the mating surfaces of the crankcase halves and wipe dry WARNINGGasoline and low flash-poin ...

Immobilizer Amplifier Replacement
Remove the upper fairing assembly (see Upper Fairing Assembly Removal in the Frame chapter). Disconnect the connector [A]. Pull out the immobilizer amplifier [B] together with the rubber protector [C] from the air intake duct [D]. ECU Replacement Refer to the ECU Removal/Instal ...

Seat Cover Installation
Installation is the reverse of removal. Note the following. When installing the pad [A], install it along the corner [B] as shown in the figure. When installing the pad [C], align the ends [D], along the corner [E], and wrap [F] the upper edge of the seat cover. Install the damper [A] ...