Product Installation Instructions for Heavy Duty Clutch Kit with Friction Plates, Springs, and Gasket for S Intruder 800 VS800GL GLV (1992-2004)

Preparation:

Before starting the installation process, please ensure that you have the following tools and materials ready:

Tools Needed:

1. Socket Set: A complete set of sockets, including metric sizes.
2. Wrench Set: Open-end and box-end wrenches.
3. Torque Wrench: To ensure proper tightening of bolts.
4. Screwdrivers: Both flathead and Phillips-head screwdrivers.
5. Pliers: Needle-nose and standard pliers for gripping and manipulation.
6. Clutch Alignment Tool: Essential for accurate alignment of the clutch plates (if not included in the kit).
7. Hammer: A rubber mallet may be helpful for tapping components without causing damage.
8. Gasket Scraper: For removing old gasket material.
9. Rags or Shop Towels: To clean and wipe down parts during the process.
10. Oil or Lubricant: For lubricating parts as per the specifications in your service manual.
11. Safety Glasses and Gloves: To protect your eyes and hands during installation.

Installation Steps:

1. Preparation: Ensure the motorcycle is on a stable surface and the engine is cool. Disconnect the battery to prevent any electrical issues during installation.

2. Remove the Existing Clutch System: Follow the motorcycle’s service manual to carefully remove the existing clutch assembly, including the cover, old friction plates, springs, and any additional components.

3. Clean the Area: Remove any old gasket material using the gasket scraper. Ensure the clutch cover and engine casing are clean and free of debris.

4. Install New Gasket: Place the new gasket onto the engine casing, ensuring it is properly aligned.

5. Install the New Friction Plates and Springs: Using the clutch alignment tool, install the new friction plates in the correct order as specified in the kit instructions. Secure with the new springs.

6. Reassemble the Clutch Cover: Carefully place the clutch cover back onto the engine, aligning it with the mounting holes. Use the torque wrench to tighten the bolts to the manufacturer’s specifications.

7. Reconnect the Battery: Reconnect the battery and ensure all electrical connections are secure.

8. Test the Clutch: Before taking the motorcycle for a ride, pull the clutch lever to check for proper engagement and ensure there are no abnormal noises.

9. Final Check: After installation, take the motorcycle for a short test ride, checking for smooth operation and making any adjustments if necessary.

Conclusion:

Follow these installation instructions carefully to ensure a successful replacement of your Heavy Duty Clutch Kit. If you encounter any difficulties, consult a professional mechanic or refer to the motorcycle's service manual for specific details. Enjoy your enhanced riding experience with improved performance and durability.