Takegawa KSR110 User manual

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2020.11.4 1/4
02-01-0404,0405,0408,0409
☆ Read all instructions 󲶻rst before starting the installation. ☆
Spcial Clutch Cover Kit (Wire-System) Instruction Manual
◎ We do not take any responsibility for any accident or damage whatsoever arising from the use of the kit not in conformity with the
instructions in the manual.
◎ We shall be held free from any kind of warranty whatsoever of products other than this product if the glitch takes place on the other
products than this one after the installation and use of this product.
◎ As brake arms and muf󲶼ers, made by other manufacturers, may interfere with the clutch cover or clutch cable. So please do not use
these brake arms and muf󲶼ers.
◎ You are requested not to contact us about the combination of our products with other manufacturers'.
◎ Please note that this kit is designed for exclusive use in the above-mentioned 󲶻tting models and frame numbers only and that it
cannot be mounted on any other models.
◎ Installation of this kit requires the disassembly and assembly of the clutch, and other work. Moreover, the use of genuine special tools is
speci󲶻ed in installing some parts. Do the installation work properly referring to a instruction manual for the relevant motorcycle models.
◎ Please consult with your motor cycle dealer for KAWASAKI about their service manual or special tools.
◎ KSR110(KL110CBF / KL110DDF), if be mounted on KSR PRO(KL110EEF), the included clutch lever ASSY. interfere with genuine control housing.
However, there is no hindrance to operation.
In the case of use in KSR PRO (KL110EEF), it does not interfere when using genuine clutch lever.
If using in KSR110 (KL110CBF / KL110DDF), use of KSR PRO (KL110EEF) for genuine clutch lever also possible.
Genuine products number：46076-0091 LEVER-ASSY-GRIP,CLUTCH
◎ This product is impossible attach to KSR PRO (KL110EEF) JKAKL110EEDA88121 ～ , it becomes possible to mounting you can purchase our
quick shift kit.
Applicable model
KSR110 ('03 ～ ) / KL110A-000001 ～
/ KL110A-A02833 ～
KSR110 (KL110CBF) / JKAKL110CCDA00058 ～
KSR110 (KL110DDF) / KL110D-A57002 ～
KLX110 ('03 ～ ) / LX110A-A08133 ～
KLX110L / LX110D-A72046 ～
Product number
KSR110
02-01-0404(with drive gear)
02-01-0405(without drive gear)
KLX110(DR-Z110)
02-01-0408(with drive gear)
02-01-0409(without drive gear)
■ Work only when the engine and muf󲶼er are cool. (Otherwise, you will get burned.)
■ Do the installation with right tools. (Otherwise, breakage of parts or injuries to you may take place.)
■ Always use a torque wrench to screw bolts and nuts tight and securely to the speci󲶻ed torque.
(Otherwise, these parts may get damaged or fall off, resulting in accidents.)
■ As some products and frames have sharp edges or protruding portions, please work with your hands protected.(Otherwise, you will suffer injuries.)
■ Before riding, always check every hardware for slack in parts like screws. If you 󲶻nd slack ones, screw them securely up to the
speci󲶻ed torque. (Otherwise, improper tightening may cause parts to come off.)
■ Always start the engine in a well-ventilated place, and do not turn on the engine in an airtight place.
(Otherwise, you will suffer from carbon monoxide poisoning.)
■ When you notice something abnormal with your motorcycle while riding, immediately stop riding and park your motorcycle in a safe
place to check what has gone wrong. (Otherwise, the abnormality could lead to accidents.)
■ Before doing work, make sure your motorcycle is secure on level ground for safety's sake.
(Otherwise, your motorcycle could overturn and injure you while you are working.)
■ Check or carry out maintenance of your motorcycle correctly according to the procedures in the instruction manual or service manual.
(Improper checking or maintenance could lead to accidents.)
■ If you 󲶻nd damaged parts when checking and performing maintenance of your motorcycle, do not use these parts any longer, and replace
them with new ones. (The continued use of these damaged parts as they are could lead to accidents.)
■ As gasoline is highly 󲶼ammable, never place it close to 󲶻re. Make sure that nothing 󲶼ammable is near the gasoline. Since vaporized
accumulation of gasoline is at high risk of explosion, work in a well-ventilated place. (Otherwise it may cause a 󲶻re.)
◎ Please be informed that, mainly because of improvement in performance, design changes, and cost increase, the product speci󲶻cations
and prices are subject to change without prior notice.
◎ This manual should be retained for future reference.
Please use a thermo unit of Item No. 02-01-5052 (coming with a gold cap) for use with this clutch cover.
Thank you for purchasing one of our products. Please strictly follow the following instructions in installing and using the products.
Before 󲶻tting the products, please be sure to check the contents of the kit. Should you have any questions about the products, please
kindly contact your dealer.
◎ Please note that, in some cases, the illustrations and photos may vary from the actual hardware.
Caution The following show the envisioned possibility of injuries to human bodies or property damage as a result of disregarding
the following cautions.
Warning The following show the envisioned possibility of human death or serious injuries to human bodies as a result of
disregarding the following cautions.
CONTACT Address：3‑5‑16 Nishikiorihigashi Tondabayashi Osaka JAPAN
TEL: ＋81‑721‑25‑1357 FAX:＋81‑721‑24‑5059 e‑mail:[email protected] URL http:// www.takegawa.co.jp
Please contact with your name and country name provided.（Only English please）
～ Features ～
● This is a kit to convert a stock automatic centrifugal clutch to a manual wire-type clutch.
● The clutch cover is made of Die-cast aluminum, buffed and coated clear paint.
● You can deliver the oil into the oil cooler from the clutch cover, and the optional of thermostat can be installed.
● To the oil hole, a stock 󲶻ller cap or an optional breather cap can be installed.
● The rack-and-pinion systems in the clutch operating mechanism, leading to improved clutch operationality.
● This kit is installable on both stock clutch or optional heavy-duty 6-disk clutch kit.
● With the optional hydraulic cylinder kit, the clutch operation can be converted from the wire-system to hydraulic system.
● Removal of a stock primary clutch and use of a special drive gear will reduce the load on the crankshaft and improve the throttle
response.
● This kit comes with a quick-release type clutch lever which can be installed or detached with a bolt only. Moreover, for installation
on KSR110, an M8 mirror holder is additionally included in this kit.

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02-01-0404,0405,0408,04092020.11.4
No. Part Name Qty Repair Part Item No.
19 Clutch cable receiver 1 00-00-2104
20 Clutch lift rod 1 00-00-1682
21 Shim ring, 9.5x20x 0.5 1 00-02-0116
22 Change-shaft return spring 1 00-02-0153
23 Primary drive gear, 22T 1 02-01-0304
24 Clutch cover gasket 1 00-02-0417
25 Clutch lever assembly 1 02-01-0601
26 Clutch lever 1 00-00-2193
27 Hex wrench, 5 mm 1
28 Clutch cable COMP., 910 mm (KSR110) 1 00-02-0107
Clutch cable COMP., 850 mm (KLX110) 1 00-02-0133
29 Socket cap screw, 6x15 1 00-00-0718 (5 pcs)
30 Socket cap screw, 6x20 1 00-00-0721 (5 pcs)
31 Socket cap screw, 6x25 1 00-00-0722 (5 pcs)
32 Socket cap screw, 6x35 8 00-00-0724 (5 pcs)
33 Mirror bracket, 8 mm 1 00-00-1695
34 Mirror bracket, 10 mm 1 00-02-0420
No. Part Name Qty Repair Part Item No.
1 Right crankcase cover assembly 1 00-02-0389
2 Oil pot window kit 1 00-02-0031
3 Clutch release pinion 1 00-02-0033
4 Clutch release rack 1 00-02-0039
5 Flat head screw, 4x10 1 00-00-0100 (10 pcs)
6 Oil plug bolt, M10x1.25 2 00-07-0072 (with washer)
7 Sealing washer, 10 mm 2 00-07-0106 (10 pcs)
8 Thermostat hole cap (silver) 1 00-07-0063 (with O-ring)
9 O-ring, 15 mm 1 00-00-0185 (5 pcs)
10 Oil seal, 10x17x5 1 00-02-0006
11 Oil seal, 16x26x7 1 00-01-0039
12 Oil sea, 12x20x5 1 00-01-0038 (2 pcs)
13 Internal circlip, 22 mm 1 00-02-0115 (3 pcs)
14 Hole cap 1 09-06-0131 (with O-ring)
15 O-ring, 30 mm 1 00-01-0034 (4 pcs)
16 Clutch release arm 1 00-02-0106
17 Clutch arm spring 1 00-00-1674
18 Plain washer, 10 mm 1 00-00-0151 (10 pcs)
※ Please note that in ordering repair parts, be sure to quote the Repair Part Item No. Otherwise, we may not be able to accept your orders.
Some parts are only available as a set. In this case, please order them with the set number.
※ In Item Nos of 02-01-0408 and -0409 is the length of the part number 28 is 850 mm.
※ In Item Nos of 02-01-0408 and -0409 is not included No. 33 and No. 34 listed above.
※ In Item Nos of 02-01-0405 and -0409 is not included No. 23 listed above.
Product content
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5 8
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7
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32 32
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2020.11.4 3/4
02-01-0404,0405,0408,0409
● This clutch cover does not operate. Without a special primary drive gear.
● The optional thermostat is usable only when an oil-cooler hose is connected to the crankcase cover. Never install the thermostat
when an oil cooler is not installed, or when the oil-cooler hose is connected to any other hardware than the crankcase cover.
● When the oil-cooler hose is to be connected from the crankcase cover, be sure to either install the thermostat or when the
thermostat is not to be installed, install a oil hole plug included in the Oil Cooler Kit. (*If the above hardware is not installed,
the engine oil will not circulate around the oil cooler.)
● NEVER install a thermostat or an oil plug bolt if you connect an oil cooler hose to either the oil 󲶻lter or cylinder-head oil pipe.
Otherwise, the engine oil will not be provided to the crankshaft, damaging the engine.
● If the oil-cooler hose is connected to the crankcase cover, only the engine oil, to be provided to the crankshaft, will circulate
to the oil cooler, and engine oil, to be provided to cylinder head, will not circulate to the oil cooler. In order to send entire
amount of engine oil to oil cooler, either connect the oil hose to the oil 󲶻lter, or install oil cooler onto either crankcase or
cylinder-head oil pipe.
Safety Precautions for Use
● Disassembly
1.Make sure the bike is secure on a sidestand.
Prepare an oil container, and detach a
drain plug to drain the engine oil.
2.Remove a kick pedal, right step-holder,
and brake pedal.
Unfasten a screw on the clutch cover to
remove the clutch cover, cover gasket and
dowel pin.
3.Remove a release lever, release ball, release
cam, ball bearing and bearing holder.
a. Release ball assembly
b. Release cam
c. Ball bearing
d. Ball bearing holder
e. Release lever
○ Except KSR PRO (KL110EEF)
4.Remove a 14mm nut, holding a primary
clutch with a special tool of primary
clutch holder.
KAWASAKI genuine special tool:
Primary clutch holder: 57001-1507
5.Remove a 14mm nut, holding a secondary
clutch with a special tool of clutch
holder.
※ Install the special tool of clutch holder,
meshing three convex portions on the
clutch holder with a concave portion on
the clutch hub.
KAWASAKI genuine special tool:
Clutch holder: 57001-1508
6.Remove the primary and secondary clutches
together.
a b c d e
Change-shaft return spring
Change shaft
● About primary clutch gear:
If the clutch gear is installed , there
will be no backlash, and the noise from
the gear will be reduced.
Without installation of the clutch gear
does not affect the clutch operation.
(Install the clutch gear only when the
kit comes with a gear.)
1.From the primary clutch housing, detach a
clutch holder, clutch holder spring, ring
and clutch gear.
2.Attach a clutch gear and ring to a provided
drive gear.
Attach a holder spring to the clutch holder.
Press the holder into the drive gear,
meshing the cogs correctly.
Put marks on any random tips of cogs meshing
together.
Clutch gear
Ring
Clutch holder spring
Clutch holder
Primary-clutch housing
1.Attach a provided change-shaft return
spring, which please install onto the
crankcase.
※ Be careful the direction of the return
spring.
Attach the change pedal, and tighten it
with a bolt.
Caution: Apply the speci󲶻ed torque.
Bolt
Torque：11.8N・m（1.2kgf・m）
☆ If you want to use to KSR PRO(KL110EEF)
(following KSR PRO), or if it is
purchased in special clutch kit, attach
the quick shift in accordance with
instructions of 1-4 of quick shift kit
installation procedure.
☆ If purchased in KSR PRO or special
clutch kit, strengthen clutch kit attach
the strengthening clutch in accordance
with an instruction of 5-9 of the
mounting procedure.
☆ When installing only in the clutch cover
kit, to perform installation work in
accordance with previous mounting
procedure 2 to instructions.
If you purchased in KSR PRO or special
clutch kit,to perform installation work
according to the instruction of mounting
procedure 3.
2.In case the clutch gear is installed to
the drive gear, give the clutch gear a
2-tooth clockwise turn. And install the
clutch gear together with the drive gear,
meshing the clutch gear with the
secondary clutch.
※ At this point, check that the marks on the
cog tips are not meshing with each other.
※ In case the clutch gear is not to be
installed, the work above is not needed.
Tighten a 14mm nut, holding a secondary
clutch with a clutch holder.
Tighten a 14mm nut, holding the primary
drive gear.
8.Remove a bolt for engine ground wire on
the crankcase.
(This is applicable only to KSR110)
7.Remove a change pedal to pull out a
change-shaft lever.
Remove a change-shaft return spring from
the change-shaft lever.
Bolt for earth wire
● Assembly and installation:
■Mounting procedure ※ With regard to the mounting method and the speci󲶻ed torque of detail, refer to the genuine service manual.
Caution: Apply the speci󲶻ed torque.
Nut 14mm
Torque：72N・m（7.3kgf・m）
Caution: Apply the speci󲶻ed torque.
Nut 14mm
Torque：72N・m（7.3kgf・m）
○ When mounted on KSR110(KL110CBF/KL110DDF) and KSR PRO(KL110EEF), the clutch lever(included in the kit)may interferes with the stock
control housing.
No problem in operation. Please be forewarned.
Stock clutch lever will not interference when using with KSR PRO (KL110EEF)
For KSR110 (KL110CBF/KL110DDF):The stock clutch lever of KSR PRO(KL110EEF)will not interference.
Genuine No.：46076-0091 LEVER-ASSY-GRIP,CLUCH

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02-01-0404,0405,0408,04092020.11.4
4.Degrease the clutch-cover mounting
surface of the crankcase.
Put in two dowel pins into the crankcase,
and attach a new clutch cover gasket.
Attach a right crankcase cover, and
fasten it with a provided socket cap
screw in a few steps in the order as
speci󲶻ed below.
6.Attach a bracket to the provided clutch
lever, and spring pin with a plastic hammer.
※ If using in KSR110, please remove genuine
mirror bracket.
※ If you are installing a rearview mirror in
KSR110, it is used in assembling the
included mirror bracket to the clutch
master cylinder ASSY.
※ For vehicles of KSR PRO(KL110EEF), the
included clutch lever ASSY is not used, it
is recommended the clutch lever use of
genuine.
①④
③②
⑦
⑧
⑨
⑥
⑤
9.Install the removed right step holder,
brake pedal and kick pedal.
10.Fasten a drain plug, and add engine oil.
※ In case a gasket on the drain plug always,
replace it with a new one.
Engine oil level: 0.9 liter (at the time of oil
change)
※ Use the following 󲶻gure just as a guideline on
how to read the oil level through oil pot window.
Important Notice
Caution: Apply the speci󲶻ed torque.
Right step-holder bolt
Torque：26N・m（2.7kgf・m）
Brake-pedal bolt
Torque：8.8N・m（0.9kgf・m）
Kick-pedal bolt
Torque：11.8N・m（1.2kgf・m）
Kick-pedal bolt
Brake-pedal bolt Step-holder bolt
Caution: Apply the speci󲶻ed torque.
Drain plug
Torque：29N・m（3.0kgf・m）
0.8L
0.9L
0.7L
Installation of oil cooler:
(In the case of installing the thermo unit)
Please be sure to use a thermo unit of
Item No.02-01-5052 coming with a gold cap.
Please note that a thermo unit of Item No.
02-01-5053 coming with a blue cap is not
usable(because of different screw diameter).
1.Install the thermo unit according to the
Instruction Manual.
2.Detach two oil plug bolts, attach hardware
like a banjo to match the kind of hose to
be used, and connect the hose.
※ Please see an Operation Manual for the
thermo unit.
※ Please see an Operation Manual for the
oil cooler kit.
(In the case of connecting the oil hose
to other hardware than the clutch cover)
NEVER install a thermostat or an oil hole
plug if you connect an oil hose to the
oil 󲶻lter or cylinder-head oil pipe.
Caution:NEVER install a thermo unit or an
oil hole plug if you do not connect
an oil hose to the clutch cover.
There is a possibility that the
engine is damaged due to the oil
passage blockage.
In case an oil cooler is not
installed:
NEVER install a thermo unit or an oil
hole plug. And in case the thermo unit
and / or an oil hole plug is installed,
DO be sure to remove it or them.
Caution:There is a possibility that the
engine is damaged because the oil
passage will be blocked when the
thermo unit or an oil hole plug is
installed.
3.Attach to spring plate the removed ball
bearing holder, and ball bearing, and
attach a provided clutch lift rod to the
ball bearing.
Attach a provided shim ring to the
change-shaft.
Shim ring
Lift rod
⑩
※ Check that a clutch release rack is
attached inside the cover.
※ Attach the right crankcase cover with
care not to damage an O-ring of a kick
shaft.
※ And jointly fasten a clutch cable
receiver and the O-ring in place.
※ Fasten an ground cord and the cable
receiver.
(This applies only to KSR110.)
Fasten cable receiver. Fasten ground cord.
(KSR110)
5.Put a 10 mm washer into the release pinion
with the washer’s round edge facing downwards.
Hang one end of a clutch arm spring on the
release arm, and the other end on the cover.
And position the release arm in place as
per the 󲶻gure below.
※ Turn the release pinion clockwise until
it comes to a halt, and attach the
release arm.
Release arm
Arm spring
about 15°
Attach a socket cap screw to the release
arm. And pressing down the release arm
lightly, tighten the socket cap screw.
7.Attach a clutch lever to the steering
handle, and tighten the bolt.
Caution: Apply the speci󲶻ed torque.
Bolt
Torque：8.8N・m（0.9kgf・m）
8.Attach a clutch cable adjuster to the
release arm.
Detach a nut on the clutch cable adjuster
completely from the screw, and pass a
cable through the clutch cable receiver.
Reinstall the removed nut, and fasten the cable
receiver in be tween nuts loosely initially.
Route the clutch cable to the clutch lever
without stretching it by force, and attach
the cable end to the lever Adjust the free
play at the clutch lever with an adjuster
on the clutch cable, and fasten thenut.
Caution: Apply the speci󲶻ed torque.
Nut
Torque：11.8N・m（1.2kgf・m）
Free play at the lever tip: 10 ～ 20 mm
※ Fine-tune the free play with the adjuster
on the clutch lever
Spring pin
Mirror bracket
Caution: Apply the speci󲶻ed torque.
Socket cap screw
Torque：8.8N・m（0.9kgf・m）
Caution: Apply the speci󲶻ed torque.
Socket cap screw
Torque：8.8N・m（0.9kgf・m）
Caution:When connecting an oil hose to the
clutch cover, you must install a
thermostat or an oil hole plug.
Without thermostat or an oil hole
plug installed,
oil will not circulate and the
engine may be damaged.
Caution: Apply the speci󲶻ed torque.
Thermostat hole cap
Torque：13N・m（1.3kgf・m）
Remove the thermostat hole cap, attach
the oil hole plug (included in our oil
cooler kit), and tighten to the speci󲶻ed
torque.
Thermostat unit or
oil drain plug hole
（When not installing the thermostat unit）