How To: Clutch Replacement Guide for Ninja 400

This 2023 Kawasaki Ninja 400 was giving the owner problems that he didn't know if they were transmission or clutch related.
Let's dig in to the clutch and see if we can find the problem, replace the clutch plates and get him back on the road as fast as possible. This is a step by step guide on how to do this and the parts used are linked below.
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Chapters:
What Are We Doing? 0:00
Where Do We Begin? 0:37
Is this Normal? 1:50
Clutch Cover Removal 4:07
Clutch Removal 6:05
Clutch Hub and Basket Removal 9:15
Reassembly 10:11
Mistakes Happen 18:30
Final Steps and Test 19:35

[@falco6414]

very interesting video! you deserve atleast a couple thousands of views

[@alexdombi-weridetwo]

Thanks! I'm hopeful that it will help people working on their own motorcycles

[@MaxVerstappen-o4p]

Hello, I’m doing the same thing except I’m just replacing plates and springs. Original judder springs have been left alone. When I put the stack back together, there is some free play with the first friction plate, it’s not solidly meshed with the rest of the stack. Any ideas why?

[@alexdombi-weridetwo]

On this bike the pressure plate needs to be seated properly. I'm sure you noticed the angled ridges on the backside of the plate. Loosen the bolts and wiggle the plate by rotating it. That may help it lock in better.

[@MaxVerstappen-o4p]

@@alexdombi-weridetwo will do, thank you 🙏

[@MaxVerstappen-o4p]

@@alexdombi-weridetwoI figured out the gap, my stack was out of order: but now the clutch cover won’t lock into place without the clutch arm being too far forward, making too much slack in the system. Is there some weird trick to doing it or is there free play in the system (perhaps the pull rod?) I’m out of ideas.

[@alexdombi-weridetwo]

​@MaxVerstappen-o4p did you make the same mistake as me with the pull rod being on the wrong side of the plate?
If no, the actuator arm takes a little finagling to get it to hook in correctly. Attaching the cable first - with it disconnected from the handle bar lever- turn the arm towards the rear wheel while putting the cover on. Once it's lined up you can rotate the arm forward. Let me know if this helps. Hopefully you get it!