Instruction Manual for Standard Kit for Special Clutch for Die
Contents
1. N Instruction Manual for Standard Kit for Special Clutch for Die Cast Cover Only for manual transmission Item No OU UU UUUU Only for TAKEGAWA made 4 5 and 6 speed crossed transmission Fitting models and frame Nos Monkey amp Gorilla Z50J 1600008 Z50J 2000001 J D AB27 1000001 0 Monkey FI D AB27 1900001 0 O Thank you for purchasing one of our TAKEGAWA made products Please strictly follow the following instructions in installing and using the kit O Before installing the kit please be sure to check the kit contents Should you have any questions about the kit please contact your local motorcycle dealer Please note that in some cases the illustrations and photos may vary from the actual hardware Features O As the clutch is installed on the secondary side on the transmission main shaft the friction loss on the crankshaft can be reduced and the crankshaft durability and throttle response can be improved We have designed the number of clutch friction disks to be five in order to correspond to the high powered engine with a large engine displacement Six pieces of dampers are fixed to the primary driven gear which works to reduce the shock felt at the time of letting in the clutch Read all instructions first before starting the installation We do not take any responsibility for any accident or damage whatsoever arising from the use of the kit not in conformity with the instruct2. A ia r x ETN SS rar Ae O0 O Remove a clutch outer cover clutch assembly primary drive gear clutch center guide and primary driven gear O DUsing a gear holder tighten the lock nut to the specified torque with the crankshaft being seated in detect and fold back the hook on the lock washer Torque 39 Nim 4 0 kgfOm X After tightening the lock nut to the specified torque turn the lock nut in the direction of tightening if the hook on the lock washer does not fit in the lock nut groove Keep other hooks in close contact with the lock nut Assembly Installation of primary drive gear O O First make sure that a stock collar is in the crankshaft Then attach a primary drive gear lock washer and conical spring washer which please fasten with a lock nut for the moment X Be careful about the direction in which to attach the conical spring washer o Mar 03 09 Clutch assembly O0 O To clutch center attach alternately one each of five friction disks and four clutch plates and then a clutch pressure plate Xx Apply engine oil to both sides of the clutch friction disk X Check that the bumpy surfaces of the clutch center and clutch friction disk are meshing well with each other O O
3. Attach the clutch spacer to the transmission main shaft Fitting the protrusion on the clutch friction disk into the groove in the clutch outer and also fitting at the same time the spline on the clutch center into the spline on the main shaft attach the clutch assembly O DIFit the supplied external circlip to the groove in the main shaft with the circlip s round corner on the downside x Don t expand the circlip more than necessary X In case you find it hard to fit the circlip into the mainshaft groove then do the work lifting up the main shaft LAS O O Place four clutch springs into the pressure plate boss and fix the clutch lifter plate with a flange bolt And tighten it to the specified torque diagonally in a few steps Torque 12 N Jm 1 2 kgf Jm Assembly of right crankcase cover and clutch cable x Please assemble these parts referring to the instruction manual for the die cast clutch cover kit x Please assemble the engine referring to the instruction manual for the relative engine SPECIAL PARTS UNAE XANA 3 5 16 Nishikiorihigashi Tondabayashi Osaka Japan 81 721 25 1357 81 721 24 5059 http Awww takegawa co jp TEL FAX URL Mar 03 09 Notice on installing Special clutch or Dry Clutch D A collar attached to a crankshaft should be used an genuine one Please noted that never attach the collar included in Takegawa Heavy Duty 3 disc clutch kit as it is differe
4. doing work place the motorcycle on level ground to stablize the position of your motorcycle for safety s sake Otherwise your motorcycle could overturn and injure you while you are working O 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 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 could lead to accidents O As 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 sTo Mer 03 09 N Kit Contents L Die cast cover kit No Part Name Oy Repar Part tem No n packs of No Part Name J Oy Repar Part tem No 1 Thrust bearing seat 1 22301 181 T00 Radial ball bearing 6001 1 00 00 0021 2 Thrust bearing 17 mm 1 ooz 1 17 Flange bok a2 a ooo o a a wase THOS f a ooo a S o flock washer 14mm 1 s0as oorroo 1 6 Radial bal bearing 6803 2 ooo 1 21 lock net COMP Anm 1 poorno r e Cuen spacer 12156 1 ceto 1 3 Bm 1 o f s m m 9 Clutch pressure plate 22350 KRL T00 1 24 Cl
5. ions 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 Please note that this kit is designed for exclusive use in the above mentioned compatible models and frame numbers only and that it cannot be mounted on other models Installation of this kit requires removal and installation of an engine disassembly ofa crankcase special tools and some processing This instruction manual as well as a HONDA s service manual is prepared for those who have acquired basic skill and knowledge Therefore those who are technically unskilled or inexperienced may not be able to install the kit correctly or may be unable to install at all leading to parts breakage This kit isn t usable on a stock transmission motorcyle An extra cost TAKEGAWA made transmission kit is indispensable This kit doesn t come with a clutch cover A TAKEGAWA made extra cost die cast clutch cover kit is necessary The installation of this Kit makes it impossible to install a stock muffler Therefore use other muffler than the said muffler Please be informed that mainly because of improvement in performance design changes and cost increase the product specifications and prices are sub
6. ject to change without prior notice This manual should be retained for future reference AN CAUTION The following show the envisioned possibility of injuries to human bodies and property damage as a result of disregarding the following cautions O Before starting the installation make sure the engine and muffler are cool Otherwise you will burn yourself Always use a torque wrench to screw bolts and nuts tight and securely to the specified 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 section for slack in parts like screws If you find slack ones screw them securely up to the specified torque Otherwise improper tightening may cause parts to come off A WARNING The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the A N WARNING following cautions 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 motorcyle in a safe place to check what has gone wrong Otherwise the abnormality could lead to accidents Before
7. nt size It will be a cause to damage if it installed In the worst case it will cause to destroy the engine As the diagram below indicates height and shape are different Please confirm Collar included in Takegawa Heavy Duty 3 disc clutch kit step CS 8mm KD 10mm Genuine collar Do not use Co There are two types of Heavy Duty 3 disc clutch kit One uses the included collar and the other one uses the genuine collar yy J an 28 13 f
8. utch release arm 22812 181 T00 Oo I Clutch friction disk 00 02 0026 I 25 Flang bolt 6x18 00 00 0023 Cir Cuh plate f a ooo 1 26 Catch release arm sping 1 22815165100 22120181 T00 C14 Ceh spins f a orero 1 S 29 Oen cable cO OO a peor 1 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 Some parts are only available as a set Please order them with the set number Ne Z aos Nar 03 09 fi oaa a I IONOS Installation Procedures This Installation Procedures relate to the work at a stage after 5 or 6 speed transmission has been installed and the engine has already been demounted from the frame For the work before this stage please refer to a service manual instruction manual or engine tuning master book Disassembly O0 O Into a transmission main shaft put a thrust bearing seat thrust bearing thrust washer and washer in this order and attach a clutch Please do the following work referring to a service manual buter COMP to ihe transmission man shan X Set the thrust bearing seat in the location so its protrusion gets stuck on the crankcase preventing it from rotating Xx Apply engine oil to the thrust washer and clutch outer ball bearing 0 O Pull out a right crankcase cover bolt to remove a right crankcase cover Detach a case cover gasket and two dowel pins Pra
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