Aluminium Clutch Cover Kit Instruction Manual
Contents
1. N G Aluminium Clutch Cover Kit Instruction Manual Item No 0 00 00 0000 Applied to Frame No Ape50 AC16 1000001 Ape50 FI AC16 1600001 Ape50 FI Type D AC18 1000001 Ape100 HC07 1000001 Ape100 Type D HC13 1000001 XR50 Motard AD14 1000001 XR100 Motard HD13 1000001 Thank you for purchasing one of our products Please strictly follow the instructions to install and use the products Before fitting the products please be sure to check the contents of the kit If you have any questions about the products please kindly contact your local TAKEGAWA dealer Please note Illustrations and photos may vary from the actual hardware Please read following instructions before installation We do not take any responsibility for any accident or damage whatsoever arising from the use of the products 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 This product is designed for exclusive use with the above mentioned type of motorcycle and frame numbers only Please take note that this product cannot be mounted on other types of motorcycles We do not have any information or service data on the combination of our products and other manufacturers products Please be informed that mainly becaus2. Remove the clutch lifter pin Put 3 pcs of shim rings through the supplied lifter pin and install them on the bearings of clutch lifter plate Bearing Shim ring x Two kinds of clutch lifter pins are available to suit the kinds of transmissions Be sure to use a 5 speed transmission lifter pin for a 5 speed transmission and a 6 speed transmission lifter pin for a 6 speed transmission U For 5 speed transmission For 6 speed transmission One line 41 3mm 40mm on the right side crankcase with the TAKEGAWA logo being visible and its y 10 Clean up case s mating surfaces attach the dowel pins and a new X Be careful not to give damages to the crank shaft and oil seals on the kick fi N Clutch lever Procedures 8 Install the clutch lever spring and Clutch lever sprin the clutch lever to the cover d Apply engine oil to the clutch leve shaft 9 Detach the oil filter screen and clean it Then fix it firmly to the grooves in the crankcase Installation of rubber separator In the case of Ape100 Ape100 Type D or XR100 Motard As shown in the photo attach the rubber separator onto the oil line groove protrusion being right in the dent of the ca
3. O eg ol rr N lutch lifter pin For 5 speed transmission 18B lutch lifter pin For 6 speed transmission Repair Parts Item No 11300 GEY T10 15413 181 T00 olololololulo N ololo oO olololol e lolo PPSP PLS PININ PIP P ZIP SIP A k CO OS S S SO wl CO oO oe Ko fo O oj o lojlolalolo ojojojojlojlole gt oe fo fo O Q 2 2 o l le 2 alol vlaj a a O OO N pat Ol O O r O e GW wi NI ol Z Ol wj e HIIS INIM AIN gt O CO CO CO HI N O Wire 0 Ol KR BR AITON T10 90145 GEY T00 15411 GEF TOO 22815 GEY TO0O 22810 GEY T02 T10 22366 GCR T10 TOO 22870 GEY T10 22872 GEY T00 00 02 0216 l ks of e x Please order repair parts with the Repair Part Item No Without the repair part item No we may not be able to provide the correct parts Ne Some parts are only available as a set Please order them with the set number N J Le Aug 22 12 N Features O We have equipped the clutch cover with an oil filter using a paper type element O A thermostat with a spring made of a shape memory alloy is available for use in this kit as an optional extra Patent granted O The clutch cover and oil filter cover are made of die cast aluminum O The surface is barrel polished O This kit enables the flow of oil from the clutch cover to oil cooler O This kit comes with an oil pot window with a high level of durability which is highly evaluated by t
4. dapter suitable for the kind of hose you will use Then connect the hose x Please see the instruction manual for the thermo unit x Please see the instruction manuals for the oil cooler kit and the adapter Allegri s hose In Case of Oil Hose Installation on the Cylinder Head Side 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 SPECIAL PARTS WN4SeYWA Co Ltd 3 5 16 Nishikiorihigashi Tondabayashi Osaka Japan TEL 81 721 25 1357 FAX 81 721 24 5059 URL http www takegawa co jp A Aug 22 12
5. e end of the clutch lever For stock lever install the clutch cable COMP while putting it through the clutch cable adapter This procedure is not required when you use TAKEGAWA Clutch Lever ASSY Return spring 14 Apply grease to the sleeve which please fix to the brake pedal and tighten loosely the spring and right side step bracket with bolts Bolts Apply the rear brake and after brake related sections get warmed up fasten the bolts to the specified torque Rear brake pedal right side step A Caution Apply the specified torque Torque 39 N m 4 0 kgf m 15 Fix the kick starter arm and screw up the bolt s to the specified torque A Caution Apply the specified torque Torque 26 N m 2 7 kgf m 16 Tighten the drain bolt to the specified torque and pour 1 000cc of engine oil A Caution Apply the specified torque Torque 25 N m 2 5 kgf m x Make sure that there is no oil leakage Appropriate engine oil level seen through the oil pot just for your guidance At oil change 0 9 liters At oil filter change 1 0 liters 1 1 liters At overhaul Apply engine oil to the O rings of the oil filter cover and install them to the Oil Cooler Installation right side crankcase cover being careful that the O rings are in the right a case a thermo uii ie to be installed N Important Notice 1 Install a thermo unit 2 Unfasten two oil plug bolts and install an a
6. e 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 A The following show the envisioned possibility of injuries to human bodies and property damage as a result of disregarding the CAUTION following cautions O Work on motorcycles only when the engine and the exhaust system are cool to avoid burns Prepare appropriate tools and work properly to avoid the breakage of parts or injuries Always use a torque wrench to tighten bolts and nuts securely to the specified torque to avoid these parts getting damaged or loose AS some products and frames have sharp edges or protruding portions work with your hands protected to avoid injuries Before riding always check such parts as screws for loose If you find loose ones screw them securely up to the specified torque to avoid parts coming off The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the IN WARNING following cautions Always drive the engine in a well ventilated place and do not switch the engine on in an airtight place Otherwise you will suffer from carbon monoxide poisoning When you notice something abnormal with your motorcycle stop riding immediately and park your motorcycle in a safe place to avoid an accident Before working place the mot
7. he Monkey model riders O Equipped with a large size oil filler cap O Lifter pin direct system which dose not utilize the cam and adjusting lever is employed as a clutch operation system Precautions for use An oil cooler unit which is installable to the oil filter cover cannot be installed to this kit due to the size difference Oil lines can be used only at the specified location A conventional oil cooler hose cannot be installed to this kit due to the size difference Please use the special one for exclusive with the die cast cover If you are using an oil cooler kit to which an oil hose is connected from the cylinder NEVER install a thermo unit or oil hole plug There is a possibility that the engine will be damaged due to the oil passage blockage Please refer to a relative instruction manual for a thermo unit an oil cooler and so on Please do the work referring to a HONDA s service manual for Ape50 Ape100 XR50 Motard and XR100 Motard About Oil Lines o Inthe case of Ape50 and XR50 Motard all the engine oil is provided to the cylinder head and the crankshaft via oil filter o An oil line in the crankcase of Ape100 Ape100 Type D and XR100 Motard differs in shape from the one in Ape50 and XR50 Motard However by attaching the provided rubber separator onto the first three types of motorcycles all the engine oil can be arranged to flow through the oil filter to the cylinder head and crankshaft just like the lat
8. orcycle on the level ground to stabilize its position for safety to avoid the motorcycle overturning Check or perform maintenance of parts correctly according to the procedures in the instruction manual or a service manual Improper checking or maintenance could lead to an accident O If you find damaged parts when checking and performing maintenance 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 an accident OAs gasoline is highly flammable never place it close to fire Make sure that nothing flammable is near the gasoline Since vaporized accumulation of gasoline is at the high risk of explosion work in a well ventilated place S J sis Aug 22 12 f Kit Contents Parts Names Right side crankcase cover assembly Oil filter spring Oil filter element O ring 40MM il filter cover ange bolt 6X16 ring 30MM Sealing washer 10MM 10 1 ring 15MM ermostat hole cap Oil seal 18X29X7 il pot window set Oil seal 12X18X5 lutch lever spring lutch lever COMP m N 3 14 5 16 17 18A m O 19 0 21 22 23 24 25 26 ight side crankcase cover gasket lutch cable receiver lange bolt 6X35 lange bolt 6X40 lange bolt 6X80 Flange bolt 6X100 Rubber separator Clutch cable COMP 27 Clutch cable adapter 28 Shim ring 12X18X0 3 N A 9 g Q 9 3 9 9 4 9 Z ze kei D a Q o
9. se x Install the rubber separator without using a hammer or the like Xx First attach the clutch cover gaskets to the crankcase And check that the arrowed hole is not blocked up by the rubber separator And lastly attach the clutch cover Make sure that this hole is not blocked up Install the rubber separator with the TAKEGAWA logo being visible Install the ____ separator with its protrusion being right in the dent of the case irit gasket and install the cover starter spindle 11 Fasten temporarily the cover with the supplied bolts and check the free play of the clutch lever The correct free play is between about 6 15 degrees about 5 10 mm You can adjust it by changing the number of shim rings attached on the lifter pin If the free play is less decrease shim rings If it is more increase shim rings When you have the appropriate free play tighten them to the specified torque in a crisscross pattern in two or more steps Aug 22 12 fia Place the oil filter spring on the protrusion of the right side crankcase cover oil filter Install an oil filter element with the rubber seal facing to the outer side position And fix and tighten the flange bolt to the specified torque A Caution Apply the specified torque Torque 9 N m 0 9 kgf m 13 Connect the clutch cable and adjust the free play on it Free play on the clutch 10 20 mm at th
10. ter two types of motorcycles Oil Line Diagram Flow of engine oil To cylinder head To cylinder head To cylinder head at Oil filter Rubber separator supplied in the Kit i To crank shaft To crank shaft To crank shaft Crankcase Right crankcase cover Crankcase Right crankcase cover Crankcase Right crankcase cover In the case of Ape50 and XR50 Motard In the case of Ape100 Ape100 TypeD In the case of stock Ape50 100 and XR100 Motard and stock XR50 100 Motard S A 53 Aug 22 12 r 1 Stabilize the vehicle with a maintenance stand 2 Prepare a tray Remove the drain bolt and drain engine oil Installation 3 Unfasten the bolt on the kick starter arm and remove the starter Unfasten two bolts on the right side step bracket and detach the bracket rear brake pedal sleeve je C and spring Right ide step ear brake pedal Return spring sleev 4 Disconnect the clutch cable Detach the engine mounting upper nuts and pull out the mounting bolts to demount the clutch cable receiver Fix the clutch cable receiver included in the kit and fasten the engine mounting nuts to the specified torque A Caution Apply the specified torque Torque 44 N m 4 5 kgf _m 5 Unfasten the bolts on the right hand Fg ae J crankcase cover and remove the right side cover Lock nut Cable receiver 6 Remove two dowel pins and a gasket Gasket 7
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