• For replacement clutch springs, use Kawasaki part 92145-0220 (ZX10)
  

22103C Antihopping clutch kit R1 2015 - mounting instructions

Congratulations, you bought the best clutch system for your R1 2015.

This clutch should be installed by an experienced service center, or experienced mechanic.

1. Read this instructions with photos before you start. Make sure the kit includes all parts .
2. Remove the old clutch ( according to the Yamaha workshop manual ), clean the threads on the shaft of old glue perfectly. Clean these parts with brake cleaner.
3. Make sure that the original thick shim under clutch drum is in its position ( pic.a).
4. Make sure the steel balls are in their pockets. Use two clutch springs and upper retainers to hold both parts of clutch drum together. Maintain the position of both clutch parts.
5. Install this unit install onto the gearbox shaft ( pic.b ).
6. The kit includes all the parts that are necessary for assembly. They are packed in position as how to mount them. Mount the shim at first (pic.c ), then the spider spring (pic.d ) and the nut (pic.e ). Nut torque is 120 Nm, use glue Loctite No. 620 (RED) to secure it ( pic.f ). Lock it also mechanically to shaft ( pic. g )
7. Remove the springs with retainers.
8. Install clutch plates and springs. This clutch is designed for STD plates and kit springs. First install a full width friction plate, then a steel, then the narrow plate and judder springs, Put the remaining clutch plates on as standard ( pic. h ) – EXCEPT last steel plate under pressure plate ( pic. i ). This steel plate is replaced with the 2.0mm steel plate from kit. After put last friction plate ( pic. k ).
9. Remove pull rod from STD pressure plate and put to kit pressure plate. Mount the this pressure plate with pull-rod (pic.l).. Install clutch springs with kit retainers and M5x 25mm kit bolts ( torque 8 Nm ) .
10. Check the clearance between pressure plate and clutch hub via the small holes in the pressure plate. The correct clearance is about 1,0 mm, minimal clearance is 0.6mm. In case it is smaller, install all new friction plates. You can also adjust this clearance also with help of the thicker 2.3mm steel plate from kit.
11. In case you use aftermarket friction plates, you can reach correct clearance by using

Suitable combination of following steel plates:

Order No. Thickness

21812 2.0

21814 2.3

12. Install clutch cover according Yamaha workshop manual, adjust clutch cable and go back to track.

LIST OF PARTS

1 pc. clutch drum lower side

1 pc. clutch drum upper side

1 pc. pressure plate

6 pcs. steel ball

1 pc. bombing washer

1 pc. spider springs

1 pc. nut

1 pc. steel plate 2.0mm

1 pc. steel plate 2.3mm

6 pcs. spring retainer basic

6 pcs. spring retainer for medium preload (more engine braking)

6 pcs. spring retainer for high preload (Even more engine braking)

6 pcs. M5 x 25 bolt