Installation Instructions – 1190 Auto Clutch

B
E
A
D
C
Please Read Carefully
Prior to Installation
• Use caution and always wear eye protection.
• Avoid skin contact with fuels and oils.
• If you don’t feel confident installing this product, please seek professional assistance.
What’s Included in your kit
A)
B)
C)
Auto Clutch Pressure Ring
Barnett Kevlar Clutch Pack
Clutch Tuning Kit (Spare Parts)
D)
E)
F)
Adjustable Slave Cylinder
Clutch Slave Bleeding Syringe
Comprehensive Instructions
* Note: the contents of your kit will vary depending on which model you’ve ordered.
PowerCell Performance • 10347 Los Alamitos Blvd • Los Alamitos Ca 90720 • 800.321.1927 www.powercellperformance.com
Installation Instructions
(Part One)
Disconnect the Brake Peddle -
Loosen and remove the bolt securing the rear
brake pushrod from the brake peddle Heim
Joint.
Disconnect the Brake Peddle Return Spring -
Reach in and disconnect the brake peddle return
spring from the tab welded to the frame. This will
allow the peddle to fall freely and provide access
the clutch side cover.
Remove the Clutch Cover -
Using an 8mm socket wrench, remove the 5
factory clutch cover bolts, noting their positions.
Next, pry the cover loose and set aside.
PowerCell Performance • 10347 Los Alamitos Blvd • Los Alamitos Ca 90720 • 800.321.1927 www.powercellperformance.com
Installation Instructions
(Part One)
Remove the Clutch Pressure Plate -
Remove the 3 bolts securing the clutch pressure plate to the clutch hub. Take turns unscrewing each of
the bolts a few turns at a time until they are all loose and can be removed. Set the screws, retaining plate
and springs aside.
Remove the Pressure Plate -
Using a screw driver or two, gently rotate the pressure plate as shown below in a clockwise direction causing
it to “unscrew” from the center hub. As soon as the pate begins to rotate you can easily lift it from the clutch
assembly.
PowerCell Performance • 10347 Los Alamitos Blvd • Los Alamitos Ca 90720 • 800.321.1927 www.powercellperformance.com
Installation Instructions
(Part One)
Remove the Clutch Plates -
Remove all of the clutch drive and friction plates, including the anti-chatter spring and washer (shown in insert).
None of these will be reused during installation as the clutch pack provided is a complete assembly.
Prepare the Clutch Pack for Assembly -
When you receive your PowerCell Auto Clutch, it arrives pre-tuned for your specific application, and no
adjustments are necissary. A small package of spare tungsten balls and return spings is included in your kit
should you wish to experiment with alternate engagement points. The auto clutch, along with the drive and
friction plates, are held closely together and arranged in the proper order needed for installation. Carefully
remove the clutch pack assembly from it’s plastic sheath and insert it into a Ziploc freezer bag. Pour enough
engine oil into the bag to fully engulf the clutch pack. Allow the discs to soak for a minimum of 30 minutes prior
to installation.
PowerCell Performance • 10347 Los Alamitos Blvd • Los Alamitos Ca 90720 • 800.321.1927 www.powercellperformance.com
Installation Instructions
(Part One)
Identifying the Clutch Plates -
Your KTM uses 2 styles of Friction discs: F1 and F2. And 2 styles of Drive plates: D1 and D2 (as seen below).
Friction Discs
F1
Drive Discs
F2
D1
D2
When installing the clutch pack, insert the discs as follows starting from the first friction disc (#17) to the final
disc (#1). Note: In the picture below, the disc on the bottom will go in first, and disc on the top will be the very
last disc you install before the pressure plate is bolted in place.
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
15)
16)
17)
F2
Clutch Cover
D2
F2
D2
F1
D1
F1
D1
F1
D1
F1
D1
Auto Clutch
D1
F1
D1
F1
Clutch Hub
PowerCell Performance • 10347 Los Alamitos Blvd • Los Alamitos Ca 90720 • 800.321.1927 www.powercellperformance.com
Installation Instructions
(Part One)
Installing the Clutch Pack -
Install the clutch pack starting with disc #17 and continue as previously outlined, aligning the drive fingers of
the friction discs with the deep slots in the outer hub. When you reach the final 2 discs (#2 and #1), you’ll need
to install them directly on to the clutch pressure plate as shown in the picture below (left). When you install
the pressure plate back on to the hub, you’ll need to align the drive plate fingers so that they fall into the
shallow slots of the hub towers as seen in the picture below (right). As you push the pressure plate into the
hub, it will rotate counter clockwise as it seats on to the inner hub.
Installing the Clutch Springs -
Insert the 3 pressure plate springs on to the spring posts and install the spring cover along with the 3 retaining
screws. When the screws start to compress the springs, gradually tighten them by hand evenly so as not to
cause the spring cover to bind. When all the bolts are seated onto the center hub, torque them to 12 Nm or
9 ft-lbs.
PowerCell Performance • 10347 Los Alamitos Blvd • Los Alamitos Ca 90720 • 800.321.1927 www.powercellperformance.com
Installation Instructions
(Part One)
Preparing the Clutch Cover -
If plan to retain the factory clutch cover, you will need to remove the noise damper plate prior to installation.
Simply remove the center bolt and pry the damper from the cover. Install the cover using the 5 factory bolts.
Finishing Up -
After installing the clutch cover, re-attach the brake peddle spring and install the bolt attaching the peddle to
the rear brake master cylinder. You have now completed the first part of installing of your PowerCell
Performance Auto Clutch. All that remains is to install the Adjustable Clutch Slave and you’re done!
Please refer to the Clutch Slave for specific installation instructions and adjustment
PowerCell Performance • 10347 Los Alamitos Blvd • Los Alamitos Ca 90720 • 800.321.1927 www.powercellperformance.com