Brocks Performance Clutch Cushion Kit ZX-10R (08-14) - Manual

DOCUMENT ID 992716
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Installation Instructions For
Kawasaki ZX-10R (2008-12) Clutch Cushion Kit
This package contains:
1 - Brock’s Performance Cushion Ring
6 - Brock’s Performance Spring Tops
6 - Brock’s Performance Heavy Duty Springs
2 - Brock’s Performance Extra Heavy Duty Springs
6 - Aluminum Spacers 0.280” Thick
Special Note: We recommend the use of a factory service manual for all
Brock’s Performance Product installations and/or maintenance.
A note before you begin: assembly is in EXACT reverse order of disassembly, unless otherwise noted.
1. Remove the clutch cover, clutch springs, pressure plate and all discs.
2. Position the small lip (on the recessed/counter bored side) of the Cushion Ring over the rear flange of the inner clutch hub.
*** DO NOT INSERT A STEEL PLATE INTO THE ALUMINUM CUSHION RING***- See Lip/Flange placement note on the clutch
assembly drawing on page 2. The installer will see the smooth side of the cushion ring when properly mounted. The cushion ring must
be CENTERED on the rear flange of the inner clutch hub; NOT resting on the splines of the inner clutch hub or tilted in any way.
3. Install the OEM base washer and judder spring over the teeth of the inner clutch hub and into the center hole of the cushion ring.
4. Position a thick STEEL plate, with the rounded edge facing AWAY from the engine, over the clutch hub until it touches the Cushion
Ring. Be careful not to disturb the Lip/Flange placement. The rounded edge is small, feel for it with your fingers. FYI: There are a total
of 9 steels and 9 fibers used: 7 steels 2.9mm (0.114”) thick, 2 steels 2.6mm (0.102”) thick, 8 fibers (large pads) and 1 fiber (small
pads). A detailed drawing is included in your Kawasaki Service Manual.
Special Note : We usually apply a SMALL amount of oil to the
friction plates before installation. There is no need to over-oil the plates!
5. Install a fiber plate (large pads) then another thick steel, this time with the rounded edge facing TOWARD the engine. The
remaining steels will be positioned in this configuration. Continue the installation: steel/ fiber, until you finish with the (2) thin steels
and the fiber with the small pads. Be sure to insert the outermost fiber drive plate claws in to the other slits of the outer basket. A
diagram is shown in your service manual.
There will be 1 fiber plate with the small pads not used.
6. Install the pressure plate, making sure that the teeth on the pressure plate mesh with the clutch hub.
7. Install the clutch springs with the supplied tops and spacers. For short wheelbase, lighter riders, use all (6) purple springs for a
static pressure of 336 lbs. (56 lbs. x 6 springs). For maximum static pressure, longer wheelbase and heavier riders, replace (2) of the
purple springs with the (2) green springs for a static pressure of 420 lbs. (56 lbs. x 4 springs + 98 lbs. x 2 springs).
The green
springs must be installed directly across from each other . When using the (6) purple springs, additional shims may be added,
but do not shim the springs below 0.79” installed height or coil bind will occur. Do not add shims to green springs . Use as much spring
pressure as you are comfortable with to increase clutch life. Tighten the bolts in a cross pattern and torque the bolts to 8 lb-ft (11Nm).
8. Replace the Clutch Cover, torque to 7.5 lb-ft (10 Nm) and adjust the clutch lever free play.
Brocks Performance Products are designed for Closed-Course Race Track use ONLY.
Brocks Performance Products policies and warranty information: www.BrocksPerformance.com
For additional information: Check our Information Forum at www.BrocksPerformance.com
E-mail [email protected] or call the Order Line 937-912-0054.
Brock’s Performance Products • 4064 East Patterson Road • Dayton, OH 45430 • Phone: 937-912-0054 • Fax: 937-912-0062