how to install factory shitft kit on ZX636

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how to install factory shift kit on ZX636

i though i'd share the run down on affromans factory shift kit install. the bikes a 03 kawasaki ZX636. you'll need the normal set of sockets, wrenches, allens, pliers, torque wrench and either and air-impact or 1 special tool. its a pretty easy instal, took me about 1.5 hours. i took pics of almost every step. good luck

 

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with the bike on its side stand remove the clutch cover bolts, they're 8mm.

the factory instuctions ask you to drain the oil, if you have the bike upright oil WILL spill out

 

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pic

 

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view with the bolts removed

 

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remove the clutch cover and loosen the clutch spring bolts

 

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.

 

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once the four bolts and springs are removed take off the outer pressure plate

 

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.

 

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remove the clutch pusher

 

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remove the clutch plates. personally i like to remove the pak as a whole unit

 

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the next step is where you need the speical tool to hold the inner clutch basket while turning the large nut inside. sometimes an air-impact is needed

 

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once the nuts removed you can remove the inner basket

 

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when removing the inner basket be careful not to drop the spaces that are on both sides of the basket.

 

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heres the 1 on the back

 

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this is all the parts. get something clean to put all the parts in

 

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insert 2 4mm allens,screws,bolts into the clutch sleeve so you can pull it out with pliers

 

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.

 

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like so

 

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now you can remove the clutch housing