Dry-Type Clutch Kit Instruction Manual
Contents
1. No Parts Name Repair part Item No in packs of Qty Repair part Item No in packs of 1 Right crankcase cover COMP 11331 KRL TOOC 1 1 00 02 0027 1 2 Clutch cover COMP 11332 GEY TOOC 1 1 00 02 0040 1 3 Right crankcase cover gasket 00 01 0097 1 1 15411 GEY T0O ae 4 Crankcase gasket 00 01 0112 1 1 00 00 0151 10 5 Main shaft for stock transmission 12T 23212 GEY T00 1 1 00 02 0112 1 Main shaft for TAKEGAWA 6 speed transmission 14T 23213 GCR TO0O 1 1 00 00 0023 2 6 Primary driven gear assembly 71T 1 23100 GEY TOOA 1 Clutch release arm 1 00 02 0106 1 7 Dowel pin 8x14 2 00 01 0317 2 Complete set of clutch cable 1 00 02 0107 1 8 Clutch outer 1 23101 165 T00 1 O ring 1 9 Flat head screw 6x15 6 00 00 0031 5 Hole cap 1 12361 GEF T00 1 10 Set ring 17 mm 1 00 02 0128 1 Complete set of oil pot 1 00 02 0031 ISET 11 Clutch pressure plate 1 22350 181 T10 1 Oil seal 60x80x8 1 00 02 0044 1 12 Clutch plate 4 00 02 0029 1 Oil seal 18x29x7 1 020 01 0017 1 13 Clutch friction disk 5 02 02 0003 5 Clutch release pinion 1 00 02 0033 1 14 Clutch friction disk B 1 00 02 0202 1 Oil seal 10x17x5 1 00 02 0006 1 15 J udder spring 1 00 02 0203 1 Flat head screw 4x10 1 00 00 0190 6 16 J udder spring seat 1 BG 000 0001 1 17 Ceh center 1 002007 T 18 Etema crp 1 0005 T 19 Clutch spring 4 22401 181 T00 1 1 50135 GEY T10 1 20 Clutch lifter plate COMP 1 22360 GEY T0O 1 46 Socket cap screw 6x40 22. Item No Applicable models and Frame No 0 0 O for stock transmission Ape50 AC16 1000001 O o O for our 6 speed transmission 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 O Thank you for purchasing one of our products Please strictly follow the following instructions in installing and using the products O Before fitting 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 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 You are kindly requested not to contact us about the combination of our products with other manufacturers This product is designed for exclusive use in the above mentioned types of motorcycles and frame numbers only Please take note that these products cannot be mounted on other types of motorcycles These products are not designed for
3. Place the removed engine on a working table to stabilize it and referring torque to the Service Manual disassemble the crankcase and take out the transmission A Caution Apply the specified torque 3 To prevent axial direction from getting out of place punch marked six Torque 10 ND m 1 0 kgff m places or six places around bearings inside the main shaft of the right x Fit the case with enough care since the oil seals of the right crankcase crankcase see picture below with a center punch Punch diagonally 3 cover set sometimes get s turned up six places about 2 mm outside outer circumference of the bearings Clutch Installation 1 Attach the clutch outer to the main shaft and temporarily tighten it with 6x15 mm flat head screws Then tighten them fully diagonally to the specified torque A Caution Apply the specified torque Torque 10 NO m 1 0 kgf m Replace the stock main shaft in the transmission with a kit s dry type 4 2 Pass a stock spline washer B through the main shaft first and then a one kits 17 mm set ring Be careful about the directions of each gear when mounting the main 3 Into the clutch center install the clutch friction disk clutch plate clutch shaft friction disk B judder spring seat and judder spring as shown in the figure below And attach the clutch plate and clutch disk alternately X Be careful about the direction of the spring when installing it
4. 00 00 0137 4 21 Flange hex bolt 6x22 4 00 02 0098 4 47 Socket cap screw 6x80 6 00 00 0351 2 22 Clutch release rack 1 00 02 0039 1 48 Socket cap screw 6x100 1 0000 0475 1 23 Socket cap screw 6x15 6 00 00 0042 10 49 Rubber separator 1 00 02 0114 1 24 Clutch cable receiver 1 22839 181 T0O 1 Tool Hex wrench 5mm 1 25 Oil filter spring 1 15413 181 T00 1 X 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 There are some parts however for which we are not in a position to accept your order in just the quantity to be used In this case please take them in the quantity packed J Aug 28 12 N O Installation Procedure O Check the contents of the kit Right Crankcase Cover Installation O Place and stabilize the vehicle firmly with a maintenance stand l 1 Degrease the mating surface of the case and fix kit s two dowel pins or the like and the right crankcase cover gasket to the crankcase 2 Apply grease to the lip of each oil seal in the crankcase cover set and Transmission l put in the case cover straight along the main shaft with care not to 1 Remove the engine referring to HONDA genuine parts service manual damage the oil seals Then temporarily fix it onto the crankcase with a hereinafter referred to as Service Manual cap screw from the center to the outside diagonally to the specified 2
5. and cost increase the product specifications and prices are subject to change without prior notice 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 manual should be retained for future reference O Features O We have changed the clutch outer from the conventional aluminum forged one to the aluminum die cast one thus increasing the durability and strength DAs the clutch section is located outside it has an excellent cooling effect Moreover since there is no oil resistance it improves the clutch disengagement In addition this dry type clutch restrains oil from deteriorating caused by the wear of the clutch disk or heat and reduces adverse effect on the engine O We increased the number of the clutch friction discs to five which accordingly can respond to a high power engine In addition by casting cast iron on the faces of discs which hit both the clutch center and the clutch pressure plate we succeeded in doing without a clutch plate which has traditionally been regarded as necessary and successfully reduced the weight In addition by compounding Kevlar fiber in the clutch friction discs we have made the discs more durable than the conventional ones The increased friction factor has brought about the decrease in the slipping judder
6. m X Apply grease to the clutch release rack 4 Attach the clutch cable end to the clutch lever 5 Connect the cable to the clutch cable without pulling it forcibly 6 Apply a little grease to the clutch cable end and put the clutch release arm X Fix the arm so its notch faces the back of the vehicle 7 Screw the adjuster of the clutch cable into the cable reciever to the end 8 Stretching the inners of the clutch arm spring and the clutch cable fix the release arm to the release pinion Then fix them by tightening the 6x18 mm flange bolt s to the specified torque A Caution Apply the specified torque Torque 10 NO m 1 0 kgf m Install the release arm by aligning the serrations with each other Otherwise the release arm will be broken and unusable 9 Adjust free play at the adjuster part of the clutch cable reciever tighten the lock nut s to the specified torque and put on the rubber caps on the clutch cable adjuster X Adjust the free play at the tip of the clutch lever to be 10 to 20 mm S 1 Put the oil filter spring inside the right crankcase cover so that it should fit in the boss Also attach the oil filter and then fix the oil filter cover by screwing 6x15 mm cap screw s to the specified torque Oil Filter Installation A Caution Apply the specified torque Torque 10 NO m 1 0 kgf m X Place the oil filter so that it sticks in the protrusion on the oil filte
7. Install the spring in the direction edged portion of the spring placed the Judder spring seat as shown in the fig below 5 Put the transmission inside the crankcases replace the crankcase gasket with a new one and fit crankcases together to screw them 6 Reinstall the parts which were detatched in disassemblying the crankcase following strictly the instructions and procedures in the Service Manual At this point leave the transmission main shaft with no parts attached to Clutch friction disk it Clutch friction disk B Primary Driven Gear Installation Clutch plate Glutehiplate Apply engine oil to the tooth face of the primary driven gear assembly Ne x Clutch center and the ball bearings and grease to the oil seal and insert the gear into the main shaft Peel the adhesive tape on the primary driven gear assembly wipe off the tape mark with thinner or the like and then apply grease thinly F Judder spring Installation of rubber separator Judder spring seat 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 on the right side crankcase with the TAKEGAWA logo being visible and its protrusion being right in the dent of the case X Install the rubber separator without usi
8. checking or maintence could lead to an accident D 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 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 latter two types of motorcycles Oil Line Diagram Flow of engine oil To cylinder head To cylinder head To cylinder head Oil filter Oil filter Rubber separator supplied in the Kit i To crank shaft Y To crank shaft f 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 and XR100 Motard In the case of stock Ape50 100 and stock XR50 100 Motard Aug 28 12 O Kit Contents
9. fter plate toward you and see if there is a clearance between the friction discs If there is a clearance this shows that the clutch center and the clutch pressure plate got out of place each other So turn the clutch lifter plate to the right or left a little until they fit each other After making sure they fit rightly fix and tighten the 6x22 flange hex bolts diagonally in incremental steps while pulling the clutch lifter plate toward you Finally tighten them to the specified torque A Caution Apply the specified torque Torque 12 NO m 1 2 kgf m In working be careful not to let the clutch springs get out of position Clutch Cable Installation 1 Referring to the Service Manual reinstall the parts in the specified order which were detached when disassemblying the crankcase Then mount the engine to the frame X Before mounting the engine replace the standard right rear engine hanger collar clutch cable guide with its counterpart in the kit 2 Attach the clutch cable receiver to the clutch cover set with the 6x15 mm socket cap screw s and tighten the screws to the specified torque 3 After making sure that there is the clutch release rack inside the clutch cover set fix the clutch cable firmly to the right crankcase cover and fix it by tightening 6x15 mm socket cap screw s temporarily Then tighten up the screw s to the specified torque A Caution Apply the specified torque Torque 10 NO m 1 0 kgf
10. ith new ones 7 1 Aug 28 12 The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the following cautions O Those who are technically unskilled or inexperienced are required not to do the work Improper installation could lead to a driver falling down or accidents as a result of parts breakage O Rotating parts in the dry clutch such as a clutch outer are touchable through an opening Please never look into it or touch it when the engine is running Moreover be dressed to protect your legs when riding so you do not get your clothes caught in the rotating parts of the clutch Other wise falling accidents and human injuries may occur O 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 O When you notice something abnormal with your motorcycle while riding down a road stop riding immediately and park your motorcyle in a safe place Otherwise the abnormaility could lead to an accident O Before doing work place the motorcycle on level ground to stablize the position of your motorcycle for safety s sake Otherwise your motorcycle could fall down and injure you while you are working O Check or perform maintenance of parts correctly according to the procedures in the instruction manual or a service manual Improper
11. lutch lever 2 Shift the transmission into NEUTRAL and start the engine Then check each section for oil leak If nothing is wrong do a test run at slow speed in a safe place to check the clutch operation SPECIAL PARTS UNAZXYNNA 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 J 5 Aug 28 12
12. ng a hammer or the like X 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 X Since remaining oil on the clutch plates will cause slipping degrease the oil finely X Check that the clutch center and the clutch pressure plate fit in each other exactly 4 Holding the boss of a clutch pressure plate align the protrusions of the clutch friction disk with the grooves of the clutch outer At the same time align the clutch center with the spline of the main shaft and insert it 5 Attach a kit s external circlip to the grooves in the main shaft Make sure Install the rubber Make sure that this that the angle of the circlip faces outside separator with hole is not blocked up x Do not expand the external circlip more than necessary the TAKEGAWA If the external circlip does not easily fit into the grooves fit it while 4 logo being kee 2 pulling the main shaft with a needle nose plier or the like visible m Q y 6 Fix the clutch spring to the boss of the clutch pressure plate Install the N separator with gt A its protrusion T being right in the na x dent of the case 4 Aug 28 12 Va 7 Attach the 6x22 flange hex bolts to the clutch lifter plate with its bearings facing outside Tighten them as hard as possible by hand Pull the clutch li
13. r cover X Unless the oil filter spring is positioned on the inside of the protrusion from oil filter there will be a gap between the oil filter cover and the right crankcase cover l X When replacing the oil filter wipe off the oil on the O ring s working face and the oil filter cover and then apply grease to the O ring thinly 2 Reinstall the parts which were detached in demounting the engine following the instructions in the service manual 3 After checking that the drain bolt s is tightened to the specified torque torque 21 5N m 2 2 kgf m put 1100cc of engine oil attach the O ring to the hole cap and tighten it to the specified torque Caution Apply the specified torque Torque 12 N j m 1 2 kgf m X Apply a little engine oil to hole cap s O ring In case you do not disassemble the crankcase at the time of an oil change put 900 cc of engine oil And put 1 000 cc of engine oil when changing the oil filter 4 Detach the spark plug and push down the kick starter a few times so the engine oil gets circulated all around the engine And then put back the spark plug where it was Only as a guide via oil window Checking after Installation 1 With the engine turned off shift the transmission to first speed and hold the clutch lever Then check that the rear wheel rotates when you move the mahine and that the rear wheel does not rotate when you have released the c
14. s and noises generated when engaging the clutch O By embedding dampers to the primary driven gear the shock or jolt at the time of engaging the clutch can be reduced O We adopted a paper type oil filter to improve the filtration property of engine oil and created an oil window to check the remaining oil amount The following show the envisioned possibility of injuries to human bodies or property damage as a result of disregarding the following cautions D Please try to ride a motorcycle at legal speed on the public road abiding by the law O Work only when the engine and the muffler are cool Otherwise you will burn yourself Prepare right tools for the work and do the work in the proper and right way Otherwise improper work could cause breakage of parts or injuries to yourself 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 pointed or protruding portions please work with your hands protected Otherwise you will suffer injuries Before riding always check every section 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 Please replace gaskets and packings with new ones Check carefully those parts to be reused and in case wear or damage is detected always E replace them w
15. use in combination with other manufacturers transmissions Installation of this product requires engine removal and mounting crank case disassembly and other work Please prepare and strictly follow HONDA genuine parts service manual for your vehicle In addtion you need to prepare gaskets and packings suitable for the specifications of your vehicle If the friction disk gets covered with water for example when running in the rain clutch slipping may occur causing the clutch to be nonfunctional If possible avoid running in the rain or when it is inevitable try to skirt a puddle as much as possible to prevent the friction disc from getting wet If a friction disc and some other parts around it get wet the clutch will not work Always wipe the water off the friction disc a clutch plate and other parts and dry them sufficiently after riding your vehicle in the rain or washing In the damp climate keep your vehicle with the clutch disengaged to prevent the friction disc the clutch plate and other parts from sticking each other In case you use an oil cooler you can take out an oil line from the cylinder side or right crank case cover by using our bore up cylinder ora seprately sold oil cooler adapter 09 07 053 054 055 X The bore up cylinder should be limited to the one with a hole on the right surface for getting the oil line out Please be informed that mainly because of improvement in performance design changes
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