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1. Remove the front exhaust pipe and the frame down tube right side floor
board and master cylinder.
2. Remove 18 cover bolts from the clutch cover, pry off the clutch cover
and note: the starter thrush washer will fall, install it on the starter
drive.
3. Remove the retaining ring from the clutch cover retaining plate. Now
remove clutch hub nut with air impact wrench counter clock wise.
4. Now remove the pressure plate torque limiter springs friction plates
and steels.
5. Soak new friction plates in motor oil for ten minutes.
6. Make sure the clutch hub housing is meshed up with oil pump drive gears
on the back side of the clutch hub before new clutches are installed.
7. On the 1500's use five new steels and two of your best used steels/on
1600's use four new steels and three of your best used steels.
8. Install new frictions and steel plates in reverse order that they came
out. Note: The outer most friction plate is installed in the shallow grooves
in the clutch hub.
9. Use grease to hold the three torque limiter springs in place on the
back of the pressure plate assembly and remember two dish together like
a flying saucer and the third dishes outward.
10. Install the pressure plate with new spring that is provided in the
kit and torque nut to 108ft.lbs.
11. Now install the pressure plate cover and snap ring. Note: Push with
your hand steadily until snap ring is installed.
12. At this time operate the clutch handle and look for separation at
the clutch hub and if you see separation go to the next step.
13. Replace or silicone old gasket to the cover and don't forget the starter
thrush washer, install the cover and the screws.
14. Replace the frame section and the front exhaust pipe and top off the
motor oil.
Congratulations! You've just installed the strongest
aftermarket clutch available for your motorcycle!
(THE GORILLA WE ARE NOT MONKEYING AROUND)
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