Kawasaki 2006 NINJA ZX-10R User Manual
Ninja ZX-10R
2006 Ninja ZX-10R
Racing Kit Manual
This manual contains only the information of the racing kit parts. Refer to the base
manual listed below for information of the original model.
Base Manual Part Number
Ninja ZX-10R
Motorcycle Service Manual
© 2006 Kawasaki Heavy Industries, Ltd. First Edition (1): Feb. 2, 2006
99924-1365-01
Congratulation on your purchase of racing kit parts for the 2006 Ninja ZX-10R.
IMPORTANT
This manual provides how to install racing kit parts for the 2006 Ninja ZX-10R and how to
tune up basically.
As for the basic knowledge, refer to the base Service Manual for the Ninja ZX-10R (P/No.
99924-1365-01).
When you participate in a race, it is necessary to modify the machine for the regulation.
So we want you to ask for the tuning up shop.
AFTER ANY MODIFICATION TO TUNE THE VEHICLE TO A COMPETITION MACHINE,
IT SHOULD NOT BE USED ON PUBLIC STREETS, ROADS OR HIGHWAYS. THE USE
OF THIS VEHICLE SHOULD BE LIMITED TO PARTICIPATION IN SANCTIONED
COMPETITION EVENTS UPON A CLOSED COURSE.
When operating the engine, be careful not to trouble persons with noise. Do not turn the
engine with loud engine and exhaust noise.
DISCLAIMER OF WARRANTY
ON OPTIONAL TUNING PARTS FOR RACING ARE NO WARRANTIES EXPRESSED OR
IMPLIED.
BASIC WORKS IN INSTALLING KIT PARTS
We are going to make up the original Ninja ZX-10R for the racing machine. We
recommend that the rider himself should do the basic works, removing parts or installing
parts etc., given advices by the tuning shop. In a race, although trouble will be apt to
happen, if you participate in basic works, you can discriminate cause of trouble, so you can
return the race soon.
But concerning difficult technical works, you should ask to tuning shop.
WARNING
CAUTION
1
Table of Contents
General Specifications .........................................................................................................3
Racing Kit Service Data.......................................................................................................5
Periodic Maintenance Chart.................................................................................................5
Engine Parts Installation ......................................................................................................7
Air Intake Parts .................................................................................................................7
Camshaft Chain Tensioner................................................................................................8
Camshafts, Sprockets.......................................................................................................9
Cylinder Head.................................................................................................................11
Cylinder Compression ....................................................................................................12
Pistons............................................................................................................................13
Crankshaft Main Journal Bushings .................................................................................15
Connecting Rod Bolts .....................................................................................................17
Connecting Rod Big End Bushings.................................................................................19
Clutch Adjustment (Back-Torque Limiter Setting) ...........................................................20
Transmission ..................................................................................................................26
Alternator ........................................................................................................................28
Water Temperature Sensor.............................................................................................32
Radiator (Kit) ..................................................................................................................32
Oil Catch Tank (Kit).........................................................................................................36
Cover Gaskets (Kit) ........................................................................................................38
ECU (Kit) ........................................................................................................................38
Frame Parts Installation.....................................................................................................39
Throttle Parts (Kit Parts) .................................................................................................39
Final Drive Parts (Kit Parts) ............................................................................................40
Brake Pads (Kit Parts) ....................................................................................................40
Seat Height Adjustment ..................................................................................................41
Front Fork Springs (Kit Parts) .........................................................................................43
Electrical System ...............................................................................................................45
Battery ............................................................................................................................45
Main Harness and Sub Harness (Kit Part)......................................................................45
Wiring Diagram (with Original Meter)..............................................................................54
Wiring Diagram (with Kit Meter)......................................................................................56
2
General Specifications
Item 2006 Ninja ZX-10R Racing
Engine:
Ignition timing 10°BTDC @1 100 r/min (rpm)
Fuel (Recommended) Racing gasoline
Engine oil (Recommended): Racing oil
Level Between upper and lower levels of oil level gauge.
Drive Train:
Primary drive reduction ratio 1.611 (87/54)
Transmission Gear Table
STD（Type A） Type B Type C Type D
1st
2nd
3rd
4th
5th
6th
In
Out
Teeth (Out/In)
Gear Ratio
In
Out
Teeth (Out/In)
Gear Ratio
In
Out
Teeth (Out/In)
Gear Ratio
In
Out
Teeth (Out/In)
Gear Ratio
In
Out
Teeth (Out/In)
Gear Ratio
In
Out
Teeth (Out/In)
Gear Ratio
13127-0020
13262-0170
38/15
2.533
13262-0185
13262-0152
39/19
2.053
See Gear
Selection
13262-0182
33/19
1.737
See Gear
Selection
13262-0166
32/21
1.525
13262-0135
13262-0183
29/21
1.381
13262-0136
13262-0171
30/23
1.304
13127-0030
13262-0267
31/13
2.385
-
-
-
-
See Gear
Selection
13262-0268
34/19
1.789
See Gear
Selection
13262-0269
31/20
1.550
13262-0265
13262-0270
29/20
1.450
13262-0266
13262-0271
29/21
1.381
13127-0031
13262-0275
34/14
2.429
-
-
-
-
See Gear
Selection
13262-0276
28/16
1.750
-
-
-
-
13262-0273
13262-0277
28/20
1.400
13262-0274
13262-0278
28/21
1.333
13127-0032
13262-0281
37/16
2.313
13262-0279
13262-0282
36/18
2.000
-
-
-
-
-
-
-
-
13262-0135
(STD)
13262-0351
30/21
1.429
13262-0280
13262-0283
28/22
1.273
3
Input 3rd/4th Gear Selection Table
4th Gear
A (=C) B
3rd Gear
A 13262-0134 (19/21) 13262-0286 (19/20)
B 13262-0284 (19/21) 13262-0264 (19/20)
C 13262-0272 (16/21) 13262-0285 (16/20)
Gear Identification Slit Number Table
Standard (Type A) Type B Type C Type D
1st
Input 0 2 3 4
Output 1 2 3 4
2nd
Input 1 - - 2
Output 1 - - 2
3rd
Input 1 2 0 -
Output 0 2 3 -
4th
Input 0 1 - -
Output 2 1 - -
5th
Input 2 0 3 -
Output 1 0 3 2
6th
Input 1 2 3 4
Output 0 2 3 4
Engine Sprocket
13144-0021 #520-16T
13144-0022 #520-17T
4
Racing Kit Service Data
Item Standard
Cylinder Head, Valves:
Valve timing:
Duration:
Intake 300°
Exhaust 292°
Camshaft timing (cam lift center):
Intake 104° (ATDC)
Exhaust 102° (BTDC)
Valve clearance:
Intake 0.22 mm
Exhaust 0.20 mm
Squish 0.85 mm
Valve to piston clearance:
Intake 1.45 mm @10°ATDC
Exhaust 1.80 mm @10°BTDC
Ignition System:
Spark plugs
Spark plug tightening torque 13 N·m (1.3 kgf·m, 113 in·lb)
These values show the specifications when standard cylinder head and gasket are used.
NGK CR9EIA-9 (STD), R0045Q-10 or
R0373A-10
Periodic Maintenance Chart
The scheduled maintenance must be done in accordance with this chart to keep the
motorcycle in good running condition.
FREQENCY
OPERA TION
Engine
Clutch plate - - check* ●
Throttle grip play - - check* ●
Spark plug - - clean/gap* ●
Engine oil - - change ●
Oil filter - - replace ●
Valve lapping ●
Cylinder head/valve - - decarbonization ●
Cylinder - - check* ●
Piston/cylinder clearance - - check* ●
Piston ring, piston, and piston pin - - replace
(When pistons 13001-0077 are used)
Piston ring, piston, and piston pin - - replace
(When pistons 13001-0078 are used)
Crankshaft main bearing - - check* ●
Each
Race
Every
2 races
●
Every
3 races
●
Every
5 races
Every
10 races
As
Required
5
FREQENCY
OPERATION
Each
Race
Connecting rod big end bearing - - check* ●
Transmission gear, bearing - - check* ●
Engine sprocket - - check* ●
Coolant - - change ●
Radiator hoses, connections - - check* ●
Frame
Brake operation - - check* ●
Brake pad wear - - check* ●
Brake fluid level - - check* ●
Brake fluid - - change* year
Brake master cylinder cup and dust seal - -
replace
Brake caliper piston seal and dust seal - -
replace
Brake hose - - replace 2 years
Drive chain - - adjust ●
Drive chain - - lubricate ●
Drive chain wear - - check* ●
Drive chain guide - - replace If damaged
Front fork - - clean/check* ●
Front fork oil - - change First change after 2 races, then every 5 races
Nut, bolt, and fastener tightness - - check* ●
Fuel system - - clean ●
Fuel hose, fuel filter - - replace ●
Steering play - - check* ●
Steering stem bearing - - grease ●
Rear sprocket - - replace ●
General lubrication of chassis - - perform ●
Wheel bearing (rear) - - grease ●
Swingarm pivot, uni-track linkage - - grease ●
Swingarm pivot, uni-track linkage - - check* ●
Every
2 races
Every
3 races
Every
5 races
Every
10 races
As
Required
year
year
*: Replace, add, adjust, clean, or torque if necessary.
6
Engine Parts Installation
Air Intake Parts
Remove the air cleaner element or cut the cleaner element off remaining the wire net to
reduce the air flow resistance.
○When removing the air cleaner element, remove the element and relational parts as
shown below.
1. Relational Parts of Secondary Air: Remove the Parts.
2. Remove the parts or cut the cleaner element off remaining the wire net.
3. Secondary Air Passages on Cylinder Head: Plug the holes, or press-fit the plugs
(92066-1005) instead of the original pins.
Output of Secondary Air on Air Cleaner: Plug the hole
4. Air Cleaner Drain Tube: Use it cutting it in suitable length.
7
Camshaft Chain Tensioner
Replace the cam chain tensioner with the kit to decrease the flutter of tensioner.
Apply the engine oil to the tensioner rod, O-ring and tensioner body, insert them into the
tensioner body.
○Check to see that the tensioner rod turns freely in the body, if not, polish the tensioner
rod or fine the female threads in the body with a tap (Diameter × Pitch = 6 mm × 1.0
mm).
Install the tensioner on the cylinder block with the tensioner rod is fully pushed back.
Turn the tensioner rod in with a screwdriver until it becomes hard to turn.
Turn the crankshaft clockwise forcing lightly to the tensioner rod with twisting force to
take up any gap and tighten the locknut.
After adjusting the tensioner rod、if the tensioner rod does not stick out from the tensioner
body, use the kit long tensioner rod (13116-1166).
NOTE
○Never forward the tensioner rod forcibly, this will increase mechanical loss of the
tensioner and may damage to the chain guide.
○The cam chain tensioner must be adjusted at every race.
1. Tensioner Body 4. O-ring
2. Tensioner Rod: 13116-1166 (Kit) 5. Locknut
3. O-ring
8
Camshafts, Sprockets
Camshafts, Sprockets:
Camshaft Duration Lift
49118-0008 (STD) (Intake) 300° 9.1 mm
49118-0045 (STD) (Exhaust) 292° 8.5 mm
49118-0034 (Kit) (Intake) 310° 9.7 mm
49118-0077 (Kit) (Exhaust) 280° 8.0 mm
Use the kit valve springs (49078-0049) when the kit exhaust camshaft (49118-0077) is
used.
○Install the kit valve springs facing the rough coiled side (pink paint end) to the retainer.
Adjust the valve clearance within the specified value. Intake: 0.15 ~ 0.24 mm, Exhaust:
0.17 ~ 0.22 mm
More performance is expected when adjusted from middle value to upper limit between
adjustable range.
If you can not adjust the valve timing for racing, install the camshaft sprocket to the
camshaft using the round bolt holes and adjust the cam chain timing according to the
Ninja ZX-10R Service Manual. If you adjust the valve timing, install the sprocket to the
camshaft between the adjustable range of the long bolt holes.
Tighten the camshaft sprocket bolts to 15 N·m (1.5 kgf·m, 11 ft·lb) of torque.
Valve Timing
Timing (cam lift center) Intake Exhaust
When the round bolt holes are used
(Original)
(Original camshaft)
When the long bolt holes are used
○When grinding the cylinder head bottom surface, grinding the cylinder top surface or
using thinner gaskets, be sure the valve to piston clearance especially.
○When using the sprocket long bolt holes and adjusting the valve timing to be different
from the standard timing, check the valve to piston clearance of all cylinders after
adjusting the valve clearance correctly.
Valve to Piston Clearance (Min.)
Intake 0.7 mm
Exhaust 1.2 mm
If the valve to piston clearance is less than the minimum value, do not start the engine
because the valves will touch the piston and the engine may be damaged.
Adjust the valve timing again to keep the valve to piston clearance more than the
minimum value.
Method of measuring clearance of valve and piston –1.
○Holding the crankshaft at 10° ATDC (intake) and 10° BTDC (exhaust) of crankshaft
timing, measure the amount of the tappet movement until the valve comes in contact
with the piston pushing the tappet.
104°
108°
(Kit camshaft)
102°
(Original or Kit camshaft)
102°
(Original or Kit camshaft)
9
Method of measuring clearance of valve and piston –2.
○Adjust the valve clearance and valve timing.
○Remove the cylinder head, and put a small piece of modeling clay on the hollow of piston
to prevent valve from coming in contact.
○Install the cylinder head and adjust the camshaft chain timing.
○Turn the crankshaft by two rotations or more.
○Remove the cylinder head and measure the thickness of the clay. The thickness of the
collapsed clay is a clearance of the valve and the piston.
10
Cylinder Head
Before reassemble the cylinder head grind off the stepped portions of the port and
smooth the inside of ports to make intake/exhaust gas flow smooth.
○Grind off the stepped portions only at the mating surface between the carburetor holder
and the intake port.
○When using the kit camshaft (49118-0034), grind off the inside of the intake port to extent
1mm from the original port diameter for improve the performance.
○Mark the carburetor holders so that they can be installed in their original positions.
○Grind off and smooth the stepped portions at the mating surface between the valve seat
and the port.
○Smooth the inside of the intake port and exhaust port.
Chamfer the machining edge of the cylinder head where the valve seat installed, also
smooth the dome of the combustion chamber with the valves installed. Excessive
smoothing may reduce the cylinder compression.
Use the hand grinder.
○Use #200 oil stone for eliminating any stepped portion and #300 oil stone for finishing.
NOTE
○These procedures make air resistance less and intake/exhaust gas flow more smooth.
However, much more ef fect can not be expected by excessive grinding and smoothing. It
may be done to the extent of getting rid of uneven surfaces.
A: Stepped Portions B: Grind off the rib to 5 mm
╳: Grind Area ( All around port )
11
The combustion chambers are modified by cutting work but the edges shown must be
hand finished for smooth corners.
NOTE
○When grinding the cylinder head surface or using thinner gasket, adjust the valve timing
to keep that the valve to piston clearance is not less than the minimum value (IN: 0.7 mm,
EX: 1.2 mm).
Cylinder Compression
To adjust the cylinder compression, adjust the thickness of the cylinder head gasket or
smooth the cylinder head under surface or cylinder top surface to make the piston squish
0.65 mm. Keep the piston squish more than 0.65 mm.
○Grind off the cylinder head under surface to 0.4 mm. Do not grind the cylinder upper
surface. This can raise the compression ratio while keeping the clearance of the piston
and valve, and one of the squish. Although, as the engine machining is uneven,
determine the cutting dimension after keeping the recess and the squish before
machining.
○Position the piston at Top Dead Center, and put a small piece of modeling clay on the
shoulder of the piston. Install the cylinder head gasket and cylinder head, and tighten the
head bolts to the specified torque.
○Remove the cylinder head and measure the thickness of the clay. The thickness of the
collapsed clay is the size of the squish.
○The most preferable squish measurement is 0.65 mm.
○Select proper cylinder head gasket.
Cylinder Head Gasket
Part No. Tightening thickness Remarks
11004-0026
11004-0052 0.60 mm KIT
11004-0022 0.55 mm KIT
11004-0034 0.50 mm KIT
11004-0023 0.45 mm KIT
0.65 mm（STD）
KIT
12
Pistons
Kit Piston: SB
(1) 13001-0077
Kit pistons are exclusive the two piston rings for reduce the compression height
(between the center of piston pin hole and the shoulder of the piston) and the
mechanical friction loss.
Kit piston has more reduced the weight compared the original piston.
To adjust the cylinder compression to 14.3, use the kit pistons and grind off the cylinder
head under surface to 0.4 mm.
○Always use the higher octane rating gasoline for prevent the knocking.
Use the kit piston rings and kit piston pins.
When replacing the kit pistons with the original pistons, inspect the squish (refer to the
Cylinder Compression section).
13
(2) 13001-0078
Kit pistons are exclusive the two piston rings for reduce the compression height
(dimension between the center of piston pin hole to shoulder of the piston) and the
mechanical friction loss.
Kit piston has more reduced the weight compared the original piston.
To adjust the cylinder compression to 14.5, use the kit pistons and remodel the original
cylinder head.
Use the kit piston rings and kit piston pins.
When replacing the kit pistons with the original pistons, inspect the squish (refer to the
Cylinder Compression section).
Remodel the cylinder head according to the following figure.
The specified squish is 0.60 to 0.65 mm: front and rear, and 0.60 to 0.67 mm: left and
right side.
Replace the cylinder head gasket with the thinner or thicker one or grind the side squish
portions of the combustion chamber and the piston head with the emery cloth if the
squish is without the specified range.
Note: Remodel the cylinder head following below.
○Grind the around the valve seats in the combustion camber until taking up the edges and
smoothing, and then polish the combustion chamber lightly. Do not polish too much
because the cylinder compression decreases.
○At this time, do so as not to damage the valve seat with the valve installed.
○Do not damage the 90°valve seating surface during the cylinder head modification.
14
Note: Use the kit pistons (13001-0077, -0078) following below.
○Use the kit connecting rod assemblies (13251-0015).
○Use the kit piston rings (13008-0019).
○There are the machining edges for the valve relief portions of the piston heads. Must be
hand finished for smooth corners. (Round the corner to R1)
Crankshaft Main Journal Bushings
The kit bushings are improved in anti-seizuring characteristics as well as in
wear-resistance as compared with the standard bushings.
Crankshaft Main Journal Clearance
※ When adjust the clearance by measurement in case aiming the clearance 0.035 mm.
15
Crankshaft Main Journal Diameter Marks
None: 34.984~34.992 mm
“1” Mark: 34.993~35.000 mm
None [C]
1: [D]
Crankcase Main Bearing Inside Diameter Marks
○: 38.000~38.008 mm
None: 38.009~38.016 mm
Mark portion: # 1~5
Crankshaft Main Journal Bushings
Color
Kit Bushing
#1.5
Kit Bushing
#2,3,4
Standard Bushing
#1.5
Standard Bushing
#2,3,4
Blue 92139-0146 92139-0149 92139-0029 92139-0032
Black 92139-0147 92139-0150 92139-0030 92139-0033
Brown 92139-0148 92139-0151 92139-0031 92139-0034
[A]: Color Mark
Thickness
1.503〜1.499
mm
1.499〜1.495
mm
1.495〜1.483
mm
16
Crankshaft Main Journal Bushing Selection
Crankshaft 1 1 None None
Crankcase
○
None
○
None
Crankshaft Main Journal Bushing Brown Black Blue
Clearance (recommend) 10 ~ 34 µm 10 ~ 34 µm 10 ~ 34 µm
NOTE
○Make the clearances between the crankshaft main journals within the prescribed
allowances. Excessive clearances will cause the oil pressure at the crankshaft main
journals to drop and lead to the damage of the bearing.
Connecting Rod Bolts
1. Original Connecting Rod
Use the original connecting bolts and nuts.
Make recesses at both ends of the original connecting rod bolt to measure its length and
determine the bolt stretch.
Connecting Rod : 13251 – 0019
Bolt : 92153 – 0491
92153 – 0809 (Spare Part : Attached Recess)
Nut : 92015 - 1311
Install the original bolts into the connecting rod.
Before every tightening, use a point micrometer to measure the length of the bolts and
record the values to find the bolt stretch.
Apply a small amount of molybdenum disulfide grease to the threads and seating
surfaces of nuts and bolts.
Tighten the big end nuts at the torque (reference torque) of 20 N·m (2.0 kgf·m, 14.5 ft·lb).
Check the length of the bolts and find the bolt stretch.
Bolt Length after tightening – Bolt Length before tightening = Stretch
Bolt Stretch
Usable Range: 0. 32 mm (0.0126 in.) target
Turn the big end nuts more until the bolt stretch reaches the usable range.
NOTE
○Replace the original bolts with new ones if they have already been tightened up to
usable range 2 times.
○Replace the bolts with new ones if they are used for the engine with a not clear feature.
17
2. Kit Connecting Rod
Connecting Rod Bolt
Use the kit connecting rod bolts (with the original connecting rod bolts) and nuts.
The kit connecting rod can use the original connecting rod bolt (92153-0491).
When using the original connecting rod bolts, make recesses at both ends of the original
connecting rod bolt to measure its length and determine the bolt stretch.
Connecting rod : 13251 – 0015
Bolt : 92153 – 0809 (Attached Recess)
Nut: 92015 - 1311
※Installation of the kit connecting rod bolt is same as installation of the original connecting
rod bolt in the 1. original connecting rod section. Refer to the 1. original connecting rod
section.
18
Connecting Rod Big End Bushings
The connecting rod bushing in the kit has improved its anti-seizure feature than standard
one.
Connecting Rod Big End Bushing/Crankpin Clearance
※When adjust the clearance by measurement in case aiming the clearance 0.050 mm.
Crankpin Diameter Marks
○: 34.493~34.500 mm
None: 34.484~34.492 mm
Connecting Rod Big End Bore Diameter Marks
○: 37.509~37.516 mm
None: 37.500~37.508 mm
[A]. Diameter Mark (○ or no mark)
[B]. Weight Mark (Alphabet, E, F et)
Connecting Rod Big End Bushings
Color
Kit Bushing Part
Thickness
Number
Blue 92139-0109 1.488 ~ 1.493 mm
Black 92139-0110 1.483 ~ 1.488 mm
Brown 92139-0111 1.478 ~ 1.483 mm
Pink 92139-0156 1.473 ~ 1.478 mm
[A]. Color Mark
Big End Bushing Selection
Crankshaft
Connecting Rod None
○ ○
○
None None
None
○
Bushing Brown Black Blue
Clearance (recommend) 34 ~ 60 µm 32 ~ 58 µm 30 ~ 56µm
※Use the pink bushings when the clearances cannot adjusted within the prescribed
allowances even if the brown bushings are used.
NOTE
○Make the clearances between the connecting rod big ends within the prescribed
allowances. Excessive clearances will cause the oil pressure at the connecting rod big
end to drop and lead to the damage of the bearing.
19
Clutch Adjustment (Back-Torque Limiter Setting)
The Ninja ZX-10R engine is equipped with the Kawasaki back-torque limiter mechanism
in the clutch. The back-torque limiter works to reduce the chance of rear wheel hop caused
by engine braking during hard braking and down shifting. The back-torque limiter operating
condition can be changed by changing the total thickness of clutch plates and changing the
number of leaf springs. Try different settings and select the best.
The standard setting of length [A], total thickness of clutch plates shown below, becomes
about 53.5 mm (t 2.9 × 7 pcs. + t 2.6 × 2 pcs.). For this setting the effective stroke of
clutch spring plate during the back-torque limiter operation is adjusted between 0.45 and
0.75 mm.
By increasing the effective stroke the back-torque limiter causes more slip. The
effective stroke increases by decreasing the length [A]. The length [A] between 51.9 and
53.5 mm is available by changing the combination of the steel plates. Replace one steel
plate with a thinner one and try the setting. If the operation of the back-torque limiter is not
enough replace other steel plates one by one.
Thickness (mm) Part Number
1.6 13089-0005
2.3 13089-0008 (STD)
2.6 13089-0009 (STD)
2.9 13089-1093 (STD)
※ The steel plate (t 1.6 13089-0005) is the standard part for ZX-6RR.
20
When decreasing the length [A], total thickness of clutch plates, use the kit spring retainers
(provided as optional production parts) to keep the preload of clutch springs according to
the table below.
Length [A] Part Number Height [H]
53.0 ~ 53.5 mm 13091-1840 8 mm
52.5 ~ 52.9 mm 13091-1041
＋Washer (92022-304)
51.9 ~ 52.4 mm 13091-1041 6 mm
※ Washer (92022-304) = Outside Dia. 11 mm
Inside Dia. 6.2 mm
Thickness 1.0 mm
※ If you have clutch slip during acceleration use shorter spring retainers by one size to
increase preload of clutch springs.
The original springs and retainers can be used if the length [A] is between 51.9 ~ 53.5
mm.
For precise setting the measurement of the effective stroke of clutch spring plate is
recommended.
• Remove oil from clutch plates.
• Hold an extra drive shaft in a vise and install the following clutch parts on the shaft.
7 mm
(6 mm＋1 mm)
21
[A] Spacers [G] Friction Plates (48 Slots)
[B] Needle Bearing [H] Steel Plates (t 2.6 mm)
[C] Bushing [I] Washer
[D] Clutch Housing [J] Spring
[E] Clutch Hub [K] Friction Plates (36 Slots)
[F] Sub Clutch Hub [L] Steel Plates (t 2.9 mm)
[M] Spring Plate
[N] Spring Retainer
22
• Engage the cam followers (Clutch Hub) with the cams (Sub Clutch Hub).
• To measure the effective stroke of clutch spring plate, set a dial gauge [A] against the
raised center [B] of the clutch spring plate.
• Move the clutch housing gear back and forth [C]. The difference between the highest
and lowest gauge readings is the amount of the effective stroke of clutch spring plate.
[D] Drive Shaft
After installing the clutch to the engine, measure and record the depth [B] shown below,
the length from the clutch spring plate to the top surface of the sub clutch hub, using a
caliper or a depth gauge. Manage the depth [B] to adjust the effective stroke after that,
because the friction disks would be worn and the length [A] would change. The decrease
of the depth [B] from the initial setting shows the increase of the effective stroke of clutch
spring plate from the value initially measured.
23
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