1. Check if the kit includes all parts
2. Remove the old clutch, clean all threads ( M8 and on the shaft )and
remove all traces of locking compound. Clean these parts with brake cleaner.
3. Mount new clutch basket, torque moment for M8 bolts is 30 - 34 Nm, use
Loctite No. 510 to secure the bolts
4. Remove O-ring from the STD spacer and install it on the
transmission input shaft. Replace old spacer with the new kit one, then
install the spring washer on top of the steel collar, and before installing
the aluminum slipper clutch hub.
5. Make sure that the steel balls are in their pockets. Use two clutch
springs and upside down spring retainers to pre-mount both parts of clutch
drum together.
6. Install the clutch hub to the transmission input shaft.
7. The kit includes the transmission nut, spider spring and an additional
curved washer. They are attached by a cable tie in the proper order. Remove
cable and mount them. Torque moment 180-190 Nm, use Loctite No. 262 to
secure the nut
8. Remove the two springs with caps
9. Install clutch plates . This kit is designed for sinter metal plates
set ( code T10909), the factory ones are identical. The set includes 9 pieces.
friction, 5 pieces. 1,5mm steel and 4 pieces. steel curved plates. The
correct total thickness of friction plates set is 22.0 mm. In case you mount
different plates, you have to maintain this thickness. When the friction
plates wear to 21.5 mm or less, replace one 1,5 mm steel plate with 2,0 mm
one. If the thickness is 21.0, replace 2 of the 1,5 mm plates with 2,0 mm
plates. In case of less than 21.0mm replace all friction plates.
10. Mount the pressure plate. Remove small O-ring from STD pressure plate
push rod, and install it to kit pressure plate. Install clutch springs with
kit Retainers and STD bolts.
11. Check the clearance between pressure plate and clutch drum in
pressure plates hole. The correct clearance is 1,0 – 1,5 mm. When the
clearance is smaller go back to point No.9. When the clearance is bigger,
you used the wrong plate set. Check your work to determine the correct stack
height. For more information stack height, click HERE
12. Pull in the clutch lever and rotate with pressure plate. Check to
see if the pressure plate lifts evenly. If the pressure plate cocks,
or does not lift evenly, re-sort clutch spring in their positions, or
install a new ones.
13. Install clutch cover and go back to track.