16403 Antihopping clutch kit ER-6 - mounting instructions

Congratulation, you bought one of the best clutch systems for your ER-6.

This clutch should be installed by an experienced Kawasaki shop, or experienced mechanic.

1. Read this instruction with photos before you start. Check if the kit includes all parts ( fig a ).
2. Remove the old clutch (according Kawasaki workshop manual), clean the threads on the input shaft and main nut from old glue perfectly. Clean these parts with brake cleaner.
3. Check the original shim under clutch drum is in its position ( pic.b ).
4. This slipper clutch is delivered assembled. Install it on the gearbox shaft ( pic.c )
5. Put spring shim ( kit ) ( pic.d ), DON´T install the original shim ( fig e ). Mount standard main nut ( pic.f ), and secure it with torque 120 Nm ( pic.g ). To secure use strong thread glue ( Würth, Berner, Loctite RED ).
6. Install the clutch plates. This clutch is designed for standard plates. Install the clutch plates to position as usual ( fig. h) )
7. Install push rod ( fig. i)
8. Mount the pressure plate. Install clutch springs with kit retainers and M5x 25mm kit bolts ( torque 8 Nm ).( fig j )
9. 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, minimum clearance is 0,35mm. When the clutch plates wear and reduce the clearance, change all friction plates.
10. Adjust clearance on clutch lever
11. Install clutch cover according Kawasaki workshop manual, and go back to track.

LIST OF PARTS

1 pc. pre mounted clutch drum

1 pc. pressure plate

1 pc. curved washer

5 pcs. spring retainer

5 pcs. M5 bolt