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.

1. Read this instruction with photos before you start. Check if the set includes all parts according to list.
2. Remount standard clutch drum according to Kawasaki workshop manual, clean the threads on the shaft and big nut of old glue with brake cleaner.
3. Check the position of the original 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 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 ).
7. Check standard pusher ( pic. k ).
8. Install pressure plate ( pic. l )
9. 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 ).

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. Clutch spring

4 pcs. Spring retainer

4 pcs. Bolt

1 pc. Nut

1 pc. Big washer