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.

1. Read this instructions with photos before you start. Check if the set includes all parts.
2. 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.
3. Check correct positioning of the shim ( original ) between basket and drum, when you replace it ( pic a).
4. Install pre mounted slipper drum ( b ).
5. Install the kit big steel washer (c ), then the original washer and original nut.
6. Tighten the big nut ( STD ) ( d ) with torque 110 Nm and secure it with glue Loctite No. 620 (RED) ( e ).
7. 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 ).
8. Reinstall STD pull rod and install it into kit pressure plate ( i ) .
9. Install pressure plate ( j ).
10. 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.

11. Every time use new clutch cover gasket.
12. 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