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:

Meter Unit Inspection
Remove the meter unit (see Meter Unit Removal). [1] Battery (+) [2] Fuel Reserve Switch [3] Ground (–) [4] Unused [5] Right Turn Signal Indicator Light (LED) (+) [6] Left Turn Signal Indicator Light (LED) (+) [7] High Beam Indicator Light (LED) (+) [8] Neutral Indicator Light (LED) (� ...

Piston Ring Groove Width Inspection
Measure the piston ring groove width. Use a vernier caliper at several points around the piston. Piston Ring Groove Width Standard: Top [A] 0.82 0.84 mm (0.0323 0.0331 in.) Second [B] 0.82 0.84 mm (0.0323 0.0331 in.) Service Limit: 0.92 mm (0.036 in.) Second 0.92 mm (0.036 in.) ...

Exploded View
EO: Apply engine oil. G: Apply grease. L: Apply a non-permanent locking agent. Lh: Left-hand Threads MO: Apply molybdenum disulfide oil solution. (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1) R: Replacement Parts S: Follow the specified t ...