Takegawa 02-01-0284 User manual

COPY
‑1‑ May./29/08
Instruction Manual Clutch Lever & Long Clutch Cable Set
・Thank you for purchasing one of our Takegawa’s products. You are requested to follow the instructions below when using and installing the parts.
・Before use, please check the contents of this product. Should you have any questions about the products, please kindly contact your dealer.
◎Please note that the descriptions in this manual like illustrations and photos may vary from actual hardware.
〜Features〜
This is a set comprising of a clutch lever and cables to be used when installing a stock clutch, Heavy-Duty Clutch Kit of Item No. 02-01-0202, 02-01-0214,
or 02-01-0506, or a Combination Switch of Item No. 02-01-015 or 02-01-018.
※The Combination Switch is for exclusive use in the Monkey and Gorilla. Therefore, we do not assume any responsibility for any glitches or any kinds
of troubles arising from the installation of this Switch on any other motorcycles than the Monkey or Gorilla, because wiring need to be processed in
this case, or we do not take any questions.
This set enables the free play adjustment at the side of the clutch lever. And its lever holder is separable. All this improves workability.
The shape of the lever is so designed that it matches the installed front brake master cylinder of 06-08-116 of our own make.
The provided clutch cable is 330 mm longer than the genuine one. (The clutch cable outer is 1,060 mm long.)
Please do read the following before starting the installation.
◎We do not take any responsibility for any accident or damage whatsoever arising from the use of the product not in conformity with the instructions
in this manual.
◎We shall be held free from any responsibility or compensation whatsoever for any glitch in the parts other than ours if the glitch takes place after the
installation and use of the products.
◎If you make modifications to any of the supplied product, we shall be held free from any guarantee.
◎You are kindly requested not to contact us about the combination of our products with other manufacturers’.
◎Please be advised that this product is designed for exclusive use in the above-mentioned suitable models and that it cannot be mounted on any other
models. The lever holder is for exclusive use with a handle pipe of 22.0 mm or 22.2 mm in diameter. Please note that the holder cannot be mounted on
any other handles of different sizes.
◎This product cannot be mounted along with a stock turn-signal switch assembly. Moreover, please take note that this product cannot be used with a
steering handle pipe to which a clutch lever holder is welded.
◎Please take note that a left-side rearview mirror cannot be installed onto this product.
◎The supplied clutch cable is longer than the one supplied in the conventional Kit. Therefore, when used in the Monkey or Gorilla, some portions of the
supplied clutch cable remains unused.
◎Please be informed that, mainly because of improvement in performance, design changes, and cost increase, the product specifications and
prices are subject to change without prior notice.
◎This manual should be retained for future reference.
・Do the installation work with right tools. (Otherwise, the installation with improper tools could cause breakage of parts or injuries to you.)
・Always use a torque wrench to screw bolts and nuts tight and securely to the specified torque.
(Improper torque could cause these parts to get damaged or fall off.)
・Always use a torque wrench to screw bolts and nuts tight and securely to the specified torque.
(Improper torque could cause these parts to get damaged or fall off.)
・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 find slack ones, screw them securely up to the specified
torque. (Or improper torque may cause parts to come off.)
The following show the envisioned possibility of injuries to human bodies or property damage as a result of disregarding the
following cautions.
CAUTION
・When you notice something unusual with your motorcycle while riding down a road, immediately stop riding and check what has gone wrong
with the motorcycle.
・Make sure your motorcycle is secure on level ground during installation. (Otherwise, the motorcycle may overturn and injure you.)
・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 find damaged parts when checking or 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.
The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the
following warnings.
WARNING
：０２−０１−０２８４ (Black)
：０２−０１−０２８５ (Silver)
：Monkey, Gorilla, DAX, etc.
：Stock manual clutch,
Heavy-Duty Clutch Kit of our make
Item No.
Fits
Suitable

COPY
‑2‑ May./29/08
３．After fixing the clutch lever assembly to the handle pipe loosely for now,
set the location of the lever, and then tighten the clutch lever assembly
with a bolt to the specified torque.
Torque: 8 N・m (0.8 kg・m)
４．Attach the provided clutch cable COMP. to the clutch lever assembly.
And run them on the vehicle body referring to how the stock clutch
cables are routed.
※In installing, apply a thin coast of grease to the ends of clutch cables
and and a pivot on the clutch lever.
５．Adjust the free play at the clutch with adjusting bolts on the clutch lever
and clutch sides.
※ Adjust the free play at the clutch lever end to be 10 to 20 mm.
１
２
〜This product includes 〜
∴Please order repair parts by indicating the Repair Part Item No. as listed
above. As you see from the list, however, there are some parts for which
we are not in a position to accept your order in just the quantity to be used.
In this case, please take the parts in the quantity packed.
No. Part Name Qty Repair Part Item No. in packs of
02-01-028 (Black) 1
02-01-0282 (Silver) 1
2
Clutch cable COMP., 1,060 mm
122870-165-T10 1
Clutch lever assembly1 1
〜Installation procedures〜
１．Detach the ends of a stock clutch cable from the clutch lever and the
clutch release arm on the engine.
２．Remove two screws on the lower part of the turn-signal-switch
housing, and separate the switch housing. Unfasten a wire band on the
handle pipe, pull out cords from the light cases and detach the switch.
Clutch wire
３．First loosen the lock nut, and then give an adjust screw a
counterclockwise turn.
４．Slowly turn the adjust screw clockwise until you encounter some
resistance.
５．Give the adjust screw about 1/8 of a counterclockwise turn from the
point where you have encountered the resistance.
６．Holding the adjust screw so it does not move out of place, tighten the
lock nut.
Torque: 10 N・m (l.0 kg・m)
７．Install the clutch cover with two screws.
１．Unscrew two screws to remove the clutch cover and gaskets.
２．Screw in the adjuster on the clutch lever all the way until it hits the stop
in order to obtain the maximum free play.
〜How to adjust the clutch free play〜
When the free play cannot be adjusted by an adjuster on the clutch
lever or on the clutch cable, adjust the free play at the clutch in the
following manner
Lock nut
Adjust screw
Adjuster
Gasket
Lifter cover
3-5-16 Nishikiorihigashi Tondabayashi Osaka Japan
TEL : [phone] FAX : [phone] URL : http://www.takegawa.co.jp
Co.,Ltd.