22003 Antihopping slipper clutch kawasaki Z800

– mounting instructions

Congratulations, you bought one of best clutch systems for your Z800 .

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

1. Read this instruction with photos before you start. Check if the set includes all parts according to list.
2. Remove the standard clutch drum according to Kawasaki workshop manual, clean the thread on the shaft and big nut from old glue with brake cleaner.
3. Check positioning of standard shim between basket and drum ( pic.a ).
4. Install pre mounted slipper drum. ( pic. b )
5. 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 ).
6. This clutch is designed for using standard clutch plates and springs. Standard clutch plate’s pack includes a thinner friction plate with steel rings on first position. NEVER install this first. Put a normal friction plate as first ( pic. g ), then a steel plate ( pic. h ), both steel rings ( pic.i ). and then the friction plate with bigger diameter . Then normal clutch plates as per original.
7. Check standard pusher ( pic. k ).
8. Install pressure plate ( pic. l )
9. Install clutch springs, install spring retainers ( kit ), and tighten all with bolts ( kit ) ( pic. m,n ).

Check 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 change all friction plates ( pic. m ).

10. 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. Spring retainer

4 pcs. Spring retainer for more preload

4 pcs. Bolt

1 pc. Nut

1 pc. Big washer