22803 Antihopping slipper clutch KTM 390 – mounting
instructions
Congratulation, you bought one of best clutch systems for
your KTM.
This clutch should be installed by an experienced KTM
workshop, or mechanic.
- Read
this instructions with photos before you start. Check if the set includes
all parts.
- Remove
the old clutch drum ( according KTM workshop manual ), clean threads on
the shaft and big nut of old glue with brake cleaner. CAUTION – left-hand
thread on the main nut.
- Check correct
positioning of the shim ( original ) between basket and drum, when you replace
it ( pic a).
- Install
pre mounted slipper drum ( b ).
- Install
the kit big steel washer (c ), then
the original washer and original nut.
- Tighten
the big nut ( STD ) ( d ) with
torque 110 Nm and secure it with glue Loctite No. 620 (RED) ( e ).
- This
slipper clutch is designed for using STD clutch plates. NEVER install the
first friction plate with thin steel rings ( judder rings ) in the first position!( pic. f ).
Install a normal friction plate at first ( g ), then a steel plate, and after
that the friction plate with bigger inside dimeter and both steel rings . Install the other clutch plates normally
( h ).
- Reinstall
STD pull rod and install it into kit pressure plate ( i ) .
- Install
pressure plate ( j ).
- Put
STD clutch springs in position as before, put spring kit-retainers, tighten
all M5 bolts with torque 8 Nm ( k ).
Check for the correct clearance
between pressure plate and clutch hub via the small holes in the in pressure plate. Correct clearance is about.
1.0-1.2 mm. Minimal clearance is 0.5mm. When this happens due to clutch wear,
change all friction plates.
- Every
time use new clutch cover gasket.
- Mount
case cover according to KTM workshop manual.
LIST OF PARTS
1 pc. clutch drum
pre mounted
1 pc. pressure
plate
1 pc. big kit
washer
5 pcs. spring
retainers
5 pcs. spring
retainers for more preload
5 pcs. bolt M5