18703 Antihopping clutch kit ZX6R 2007-2012 -
mounting instructions
Congratulation, you bought one of the best
clutch systems for your ZX6R.
This clutch shoul dbe installed by an
experienced Kawasaki service center, or experienced mechanic.
- Read this instruction with photos before you start. Check if the
kit includes all parts.
- Remove the old clutch ( according Kawasaki workshop manual ),
clean the thread on the shaft of old glue perfectly. Clean these parts
with brake cleaner.
- Check if the original spacers between bearing and clutch drum are
in position ( pic.a)
- Confirm the steel balls are in their pockets. Use two clutch
springs and upper spring retainers to clamp both parts of clutch drum
together. ( pic. b )
- Install the clutch to gearbox shaft ( pic. c )
- The kit includes small parts for mounting. Mount spring washer (
pic d ), spider spring ( pic.e ) and main nut ( pic.f ). Nut torque moment
120 Nm ( pic.g ), use glue Loctite No. 620 (RED) to secure.
- Remove the two springs with retainters.
- Install clutch plates . This kit is designed for STD clutch
plates. Correct thickness of clutch plates pack is 40.0mm, for which is
this clutch designed. Due to manufacturing tolerances, this total
thickness is not always 40mm. If
the thickness is different, you can correct this thickness with help of
different thickness of steel plates:
Catalog No. Thickness
13089-0008 2.3mm
13089-0009 2.6mm ( standard)
13093-1093 2.9mm
Don´t install
friction the plate with larger inside diameter with two steel rings if possible
( pic. j), but rather use all normal friction plates. If this is not possible,
never mount this special friction plate onto first position. Install a normal
friction plate and steel first. ( pic.k ). Then install the special fricton
plate with judder springs. Finish the pack as normal.
- Mount the pressure plate
with pull-rod ( pic.l ). Install clutch springs with kit buckels ( pic.m,n
) and M5 kit bolts ( torque 8 Nm ).
- Check the clearance between pressure plate and clutch hub via the
holes in the pressure plate. The correct clearance is about1.0 mm. This clearance can be corrected according
to step 8. When clutch plates wear and the clearance is reduced to 0.50mm replace
all friction plates to with new ones.
- Install clutch cover according Kawasaki 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.
presure plate
6 pcs. steel ball
1 pc.
curved washer
1 pc.
spider spring
1 pc.
nut
6 pcs.
spring retainer
6 pcs. spring retainer + preload ( green )
6 pcs. spring retainer + even more preload ( black )
6 pcs.
M5 bolt