20503 Antihopping clutch kit ZX10R - mounting instructions

Congratulation, you bought one of the best clutch systems for your ZX10.

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

1. Read this instruction with photos before you start. Check if the kit includes all parts.
2. Remove the old clutch ( according Kawasaki workshop manual ), clean the thread on the shaft from old glue perfectly. Clean this part with brake cleaner.
3. Check if the original spacer between bearing and clutch drum is in position.
4. Check, if the steel balls are in their pockets. Use two clutch springs and upper spring retainers to clamp both parts of clutch drum together.
5. Install the clutch to gearbox shaft ( pic. a )
6. The kit includes all small parts for mounting. Mount spring washer ( pic b ), spider spring ( pic.c ) and main nut ( pic.d ). Nut torque moment 120 Nm , use glue Loctite No. 620 (RED) to secure.
7. Remove the two springs with retainers.
8. Install clutch plates. This kit is designed for STD clutch plates. however. we need to use the 2.3 mm steels to add an extra friction
9. Use 11 of the 13088-0013 friction plates and 10 of the 13089-0008 2.3mm thick steels
10. Correct thickness of clutch plate pack is 53.8mm, for which this clutch is designed. Due to manufacturing tolerance variations, this total thickness may not be 53.8mm. In that case, 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

Also if you use Kawasaki kit „judder ring“, compensate it´s thickness with help of different steel plates.

Don´t install friction plate with larger inside diameter with two steel rings if possible ( pic. j), but rather use all same type friction plates. If this is not possible, never mount this special friction plate onto first position but install a normal plate first, ( pic.e ).

The special friction with its judder rings would be installed as the second friction plate in the pack.

9. For 2016 and newer, press out the bearing in pressure plate, install the shim, and replace the bearing.
   
10. Mount the pressure plate with pull-rod ( pic f ). Install clutch springs with kit retainers ( pic.g ) and M5 kit bolts ( torque 8 Nm ).
11. Check the clearance between pressure plate and clutch hub via the small holes in the pressure plate. The correct clearance is about 1.5 mm. This clearance you can correct according to step 8. When the clutch plates wear and the clearance is 0.80mm or change all friction plates to new ones.
12. 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. pressure plate

6 pcs. steel ball
1 pc. Shim for 2016 and newer

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