Your email address will not be published. Kawasaki Clutch Assist Spring is designed to assist the clutch lever to return back to its normal resting starting point. To know if a leak is behind the running problems, spray WD40 around the vacuum lines and intake manifolds. Then lean the bike over on the kickstand, or lean it against something sturdy if you have removed the kickstand. How to install an R6 throttle tube to shorten the throttle throw on your Ninja 400. CRG RC2 Clutch Lever Kawasaki Ninja 250R / 300 / 400 2008-2019 $ 109. If you are building a critical race bike for a national series or to challenge for a championship. Install the OEM pull rod into the end of the input shaft and install Yoyodyne pressure plate. Get the lowest price, free shipping deal, easy exchanges and no restocking fees - Guaranteed! This problem is caused by a defect in the bike’s design, which forces the clutch plates to wear out. Blue CNC Shorty Brake Clutch Levers For Kawasaki Ninja ZX 6R 07-14 Control Hand (Fits: Kawasaki) 4 out of 5 stars (1) 1 product ratings - Blue CNC Shorty Brake Clutch Levers For Kawasaki Ninja … If you are installing a Yoyodyne 5 spring clutch, scroll down to instructions 12b below. Then secure the shift lever back on the shaft and tighten it in place. 2 new & refurbished from $32.44 ... 1 product ratings - NEW 2011 - 2016 GENUINE KAWASAKI NINJA 1000 CLUTCH CABLE 54011-0109. © Copyright Norton Motorsports. Install race spec clutch upgrade kit – Clutch slipping, poor shifting, false neutrals, and dropping gears fixed and explained! According to owners, the outer brake pads on the Ninja 300s wear out rapidly compared to the inner pads. 4.5 out of 5 stars 18. So even if you’re trying to be smooth, it’s very difficult to apply a lot of power during a start. Install the Barnett Heavy Duty Clutch Springs and the spring plate and torque the spring plate bolts to 10Nm (89 inlbs) with a 10mm socket. A motorcycle transmission uses the shift star to force the shift drum to rotate to specific points where each gear is fully engaged, defined by the notches between each point on the shift star. Ninja400R Race Spec Clutch Upgrade Kit. Anti-Lock Brake System (ABS) malfunctions. Instagram A rider will attempt to shift from 5th gear to 6th gear, only for the transmission to pop back into 5th gear. I recommend using an impact gun to torque this nut. Fits your 2018 Kawasaki Ninja 400 ABS. So it could be a case of the weather affecting engine temperatures. Make sure the bearing is in place. Sportbike Track Gear is the #1 online eCommerce site for protective motorcycle apparel and performance parts. The OEM clutch configuration uses 5 friction plates, but 3 of them are narrower than the other 2. There are issues. Two different solutions to the same problem. 10% savings 79. The Kawasaki Ninja EX400cc has had several issues with the clutch “Free Play” and not pulling the … We may earn commissions through our links. Some issues owners have associated with the slipping clutch problem include: Excessively high RPMs Step 2. Here are some advantages of the Ninja 250/300/400 bikes: Thanks to their low sticker price and improved ergonomics, these bikes are a good choice for anyone looking for affording city-friendly sportbikes. This can extend the life of your clutch even more, but there is a trade-off of this. Install race spec clutch upgrade kit – Clutch slipping, poor shifting, false neutrals, and dropping gears fixed and explained! However, this doesn’t mean they are slouches, either. Since the clearance issue we addressed with our modified pull rod was an interference between the input shaft, the pull rod, and the bearing, any of these 3 parts could be modified to solve the clearance. The sturdy Delrin spacer will absorb impact in the event of a crash to keep the shaft in place and protect your engine. Install the new Blueprinted Shift Change Shaft into the engine. 95. This makes the bike feel very smooth for new riders as the bike decelerates with less engine braking feel than it would normally have. Red spacers will allow the clutch to slip more for less engine braking. Black spacers will allow the clutch to slip less for more engine braking. This causes the bike to lose speed abruptly and may lead to crashes. This poor fitment of the OEM shift change shaft makes shifting clunky and unreliable. CNC Adjustable Short Brake Clutch Levers For Kawasaki NINJA 250R 2008-2012 / Z250SL 2016-2017 / NINJA 300R Z300 2013-2017 / VERSYS 300X 2017/ Z125 pro 2017 / KLX125/D-TRACKER125 10-16 / KLX250/D-TRACK. This is labor intensive, but sometimes it’s the only solution and is considered mandatory by top level race teams. Shimming the OEM shift change shaft to move it to the left in the bike can  provide slightly better engagement of the shift paw and the dogs on the shift star, but the free play in the shift paw can still cause clunky shifting and depending on the position and play in your particular shift paw, shimming can actually cause the shift paw to contact the face of the shift star causing more shifting issues. The shift change shaft is only held in place by a small snap ring and in the event of a left side tip over, can easily be forced free from the snap ring and into the engine causing damage inside the clutch and leaking oil. More about us. ***2020 bikes STILL have the rest of the issues and STILL benefit from fixing the rest of the issues!***. Motorcycle transmissions operate by a series of gears with drive dogs and/or slots that are engaged or disengaged when the gears are shifted. Hey guys, new to this, I have a 2004 Honda 400ex, I took the clutch case off to time my machine and put it back on, now when I pull the clutch it will not engage, the lever has the usual play and it takes the usual strength to pull it in but it will not engage, please help, thank you. CRG Kawasaki Ninja 400 18-20 RC2 Brake Lever. Or just a bike that you plan to keep for awhile and want reliable, consistent shifting without dropping gears, transmission undercutting may be worth the investment for you. We share projects and helpful information. The engine must be removed from the bike and torn down all the way to splitting the cases to remove the transmission. Before you buy any Ninja 300, ask if it has had ABS issues and if the unit has been replaced. This reduced weight makes it easier for novice riders to control these bikes. We would love to hear your thoughts! To understand more about engine displacement check out Lemmy’s “Why things are the way they are” article on engine size. $110.00 $64.95. In more severe cases, the bike may stall permanently. $89.95 $ 89. Step 6. It must rotate as you seat it. Move the O2 sensor cable free from the cable clamp, and remove the clutch cover using an 8mm socket. However, now that new OEM 2020 parts are available and inexpensive, we will be discontinuing our Race Spec modified pull rod and you can now purchase the updated 2020 OEM parts for your 2018-19 directly from us and save yourself some money! This problem is caused by a defect in the bike’s design, which forces the clutch plates to wear out. And the basket and pressure plate assembly has .836″ of clearance before it bottoms out when it is removed from the bike. Our Protection Spacer is machined from Delrin to fit over the snap ring and install between the shift arm and the engine case on the left side of the bike. 4.6 out of 5 stars 16. Norton Motorsports GP Spec Kawasaki Ninja400R. Purchase 2018 Kawasaki Ninja 400 Exhaust, Rearsets, Tires and Parts from SportbikeTrackGear.com. Our Ninja400R  Clutch Cable Spring Kit includes a spring and two washers to be installed on the clutch cable to return the cable all the way. Slipper clutch KAWASAKI NINJA 400: 23504: Pressure plate: 23506: Spring retainers set: 23508: Big washer: 23509: Steel clutch disc 1 pc. Judder springs are used to help smooth the transition between the clutch being engaged and disengaged and reduce vibrations that can happen as the clutch engages. Many people, especially beginner riders, love these bikes as they are cheap and easier to ride compared to the bigger sportbikes. This is one of the most prevalent problems facing Ninja 400 owners. Step 9. Included with our Blueprinted Shaft is our Protection Spacer for the shift shaft. Moreover, the reliability of the Ninja 250/300/400 means they make for practical means of transportation. $21.99 $ 21. Step up your game with the new Ninja400R Clutch Cable Spring Kits! Poway, CA 92064. This is the intended “slipper” effect of the clutch. Step 10. Approachable power, superb ergonomics and class-leading performance offer a smooth, manageable ride that's ideal for new riders while also alluring experienced riders. I'm happy to try to answer your question on your Ninja and am sorry that you are having issues. This makes the bike incredibly difficult to launch in a race, and forces you to hold the clutch just before the engage point with the plates spinning across each other much longer when launching the bike than you would have to with other bikes. As you increase the thickness of the entire clutch pack, you also increase the amount of clutch wear that is available before the basket or pull rod will bottom out. According to them, the transmission becomes stuck, and efforts to accelerate or decelerate yield no results. Remove the washer and wipe the shaft and seal clean. There are three problems acting together to cause this issue in essentially every Ninja 400 and Z400. In this article, we will review some recurrent issues experienced by owners of the Ninja 250, 300, and 400 models. While this definitely improved performance, it led to abnormal engine stalling on some models. Neutral is defined by a notch in the point of the star between 1st gear and 2nd gear. What is transmission undercutting? In most cases, riders report that they can’t shift the gears on their bikes because of one problem or the other. Our Race Spec Shift Star has reshaped, smaller and sharper points between gears so that the roller cannot accidentally stop on the point and must fall into the next gear’s notch. The third issue here is that with the super lightweight OEM clutch springs, there’s barely enough force in the springs to return the clutch cable all the way to allow the clutch to completely engage. But there is another interesting byproduct of this slipper clutch design. From complaints online, it seems the clutch on the Ninja 400s slips. 95. Required fields are marked *, Email: sales@norton-motorsports.com Especially so since I've installed upgraded springs to help delay this exact issue. (PS: We read ALL feedback). Step 12b (Install Yoyodyne 5 Spring Slipper Clutch). Compared to their other Kawasaki cousins, the Ninja 250/300/400 are lighter. Kawasaki makes some of the best sportbikes on the market. From complaints online, it seems the clutch on the Ninja 400s slips. DMP Fender Eliminator Kit Kawasaki Ninja 400 2018-2021 $ 44. 99 $ 71. Here’s an example of a false neutral that happened to me in a race right after the start going into turn 1. The Ninja 400 provides plenty of bike for new riders to grow into. 99. $5.30 shipping. eBay; eBay Motors; Parts & Accessories ... Kawasaki Ninja 400 Complete Clutch Cable 54011-0627. The Ninja 300 replaced the Ninja 250 model, and unlike the latter, it used fuel injection instead of carburetors. Step 11. If you replace all 3 2.0mm plates with 2.3mm plates, your clutch will barely slip at all, even under hard deceleration, and your cable adjuster will likely be all the way at the end of the adjustment, so pay attention and test it out if you want to try this. 12925 Brookprinter Place, Suite 200 You can easily Google “Ninja 250 clutch lever noise” to see potential solutions to this issue. Based on research, these are the most common problems associated with the Ninja 250, 300, and 400 models: Most owners report that their bikes run rough on occasions. It falls out easily when the pressure plate is removed. Install an R6 Throttle Tube – How to install an R6 throttle tube to shorten the throttle throw on your Ninja 400. I recommend using an impact gun to torque this nut. Depending on how much wear is in your clutch, we often recommend replacing the plates with heavy duty Barnett plates at the same time that you replace the springs since you already have the clutch taken apart. Less clutch slip is a trade off for less clutch wear and more engine braking. When a particular gear is engaged, it’s drive dogs are meshed with the gear next to it to transfer power. Then use a 5mm hex to remove the bolt and carefully remove the shift star. “Undercutting”, or “back-cutting”, is a process where these square shaped drive dogs and slots are cut at a small angle, so that when they are meshed together, the power applied to them actually forces them together and it’s impossible for them to slip free while under load. According to some complaints, the bike stops running when the rider reduces throttle input i.e., slows down. Dominar 400 works this also means that the clutch pull rod and some of the clutch to! Can easily Google “ Ninja 250 model, and dropping gears fixed and explained am sorry that you are issues... 4/22/2020, we overlooked it before but have now confirmed exactly what Kawasaki changed for 2020 and... 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