21203 Antihopping slipper clutch GSX1100S katana – mounting
instructions
Congratulation, you bought one of best clutch systems for
your Katana.
For best results, this clutch should be installed by
experienced Suzuki workshop, or mechanic.
- Read
these instructions with photos before you start. Check if the set includes
all parts.
- Remove
the old clutch drum ( according Suzuki workshop manual ), clean the threads
on the shaft and big nut of old glue with brake cleaner.
- Put
shim ( original ) between basket and drum, when you replace it ( pic.a ).
- Install
the pre-mounted slipper drum ( pic.b ).
- Install
the kit steel washer ( pic.c ).
- Tighten
the big nut ( original ) with
torque 127 Nm and secure it with glue Loctite No. 620 (RED) ( pic. d,e )
- This
slipper clutch is designed for using standard clutch plates. However, do
don´t use the first and last steel plates. Put one friction plate first (
pic.f ) The remaining plates mount as standard ( pic.g ) and finish with friction plate
on the end.
- Remount
pull rod from pressure plate and mount it into kit pressure plate ( pic.h,
i, j ).
- Install
pressure plate ( pic.k ).
- Install
clutch springs ( from kit, or OEM
GSXR1000 K5 ) , install spring kit-retainers, tighten all with M5 bolts with torque 8 Nm. (
pic.l )
Check for the correct clearance
between pressure plate and clutch hub via the small holes in the pressure plate.
Correct clearance is about1.2 mm. Minimal clearance is 0,6 mm. When the clutch
plates wear to this thickness, change all friction plates to new ones.
- Every
time use new clutch cover gasket.
- Mount
case cover according to Suzuki workshop manual.
TUNING TIPS
-
In case you have strong tuned up engine, the clutch can
slip under acceleration. Use KIT spring retainers for more preload
-
in case, you prefer more engine back torque, use shorter
spring retainers for more preload
LIST OF PARTS
1 pc. clutch drum
premounted
1 pc. pressure
plate
1 pc. steel washer
5 pcs. spring retainers
5 pcs spring retainers
for more preload
5 pcs. bolt M5