19003 Antihopping slipper clutch ZX636 2003-04
– mounting
instructions
Congratulations, you bought one of best clutch systems for
your ZX636 .
This clutch should be installed by an experienced Kawasaki
workshop, or mechanic.
- Read this
instruction with photos before you start. Check if the set includes all
parts according to list.
- Remount
standard clutch drum according to Kawasaki workshop manual, clean the threads
on the shaft and big nut of old glue with brake cleaner.
- Check the
position of the original shim between basket and drum ( pic.a ).
- Install
pre mounted slipper drum. ( pic. b
)
- Put
steel ( kit ) washer ( pic. c ) and the kit main nut ( pic.d ). Tighten the nut with torque 127 Nm
and secure it with glue Loctite No.620 (RED) ( pic. e,f ).
- This
clutch is designed for using standard clutch plates and springs delivered
from Honda.. The standard clutch plate pack includes a thinner friction plate
with steel rings on first position. NEVER install this first. Put a normal
friction plate first ( pic. g ), then a steel plate ( pic. h ), then both
steel rings ( pic.i ). And after that the friction plate with bigger inside
diameter. The remaining plates mount as standard. ( pic. j ).
- Check standard
pusher ( pic. k ).
- Install
pressure plate ( pic. l )
- Install
clutch springs, install spring retainers ( kit ), and tighten all bolts (
kit ) .
Check for the correct clearance
between pressure plate and clutch hub via the small holes in the pressure
plate. Correct clearance is about. 1.2mm. When the clutch plates wear, and the
clearance is less than 0.4mm replace all friction plates ( pic. m ).
- Install
the case cover according to Kawasaki workshop manual, always use new cover
gasket
PARTS LIST
1 pc. Pre mounted
slipper drum
1 pc. Pressure
plate
4 pcs. Clutch spring
4 pcs. Spring retainer
4 pcs. Bolt
1 pc. Nut
1 pc. Big washer