Instruction Manual for Standard Kit for Special Clutch for Die-Cast Cover(Coming with a kit for 3-speed close transmission gear)
Item No.：０２−０１−５０１１ (Only for 3-speed transmission)Compatible Models and Frame Nos:
XR50R ：AE03-1000001〜
CRF50F ：AE03-1400001〜
・Thank you for purchasing one of our TAKEGAWA-made products. Please strictly follow the following instructions in installing and using the kit.
・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.

Features○ With this kit, a cetrifugal clutch transmission can be changed to a manual one.
○ 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.
○ This kit comes with a 3-speed close ratio gear set, which is compatible with a bore up kit and suitable for off-road driving.

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 instructions in themanual.
◎ 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 theinstallation and use of the kit.
◎ If you make modifications to any product of the kit, we shall be held free from any guarantee of the 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.
◎ This kit doesn’t come with a clutch cover. A TAKEGAWA-made extra-cost die-cast clutch cover kit is necessary.
◎ This kit cannot be used on a stock transmission. Install the supplied gear kit.
◎The supplied clutch lever is for installation on a handle pipe of 22.2 mm in diameter. The clutch lever cannot be installed onto a stock handle pipe. A changeof handle pipe is necessary.
◎ The installation of this kit makes it impossible to install a stock muffler. Therefore, please use our TAKEGAWA-made racing muffler and exhaust muffler(Item No. 04-01-012).
◎ Installation of this kit requires removal and installation of an engine, disassembly of a 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 technicallyunskilled or inexperienced may not be able to install the kit correctly or may be unable to install at all, leading to parts breakage.
◎Unlike general stock-cars, XR50R and CRF50F are for use in racing only as off-road motorcycles. And unlike general mass production motorcycles, these
two models are unwarranted, which please note beforehand.
◎ 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.
The following show the envisioned possibility of injuries to human bodies and property damage as a result of disregarding theCAUTION following cautions.

・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.)
The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding theWARNING 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 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.)
・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 themwith new ones. (The continued use of these damaged parts could lead to accidents.)
・As gasoline is highly flammable, never place it close to fire. Make sure that nothing flammable is near the gasoline. Since vaporized accumulation ofgasoline is at the high risk of explosion, work in a well-ventilated place.
‑1‑Jul./02/ 07

Kit Contents

３５１８３４１９２０５２１１２３４２２２３９８６２９３３１１７６３２３１１２３０１４１５１６１０１７２４１３２５２６２７Die-cast cover kit
３９２８２８４０３７３８３６No.
1234567891011121314Part Name
Thrust bearing seat
Thrust bearing, 17 mm
Thrust washer, 17x30x1Washer, 17x23x0.5
Clutch outer COMP., 67T
Radial ball bearings, 6803
Distance collar
Clutch spacer, 17x21.5x3
Clutch pressure plate
Clutch friction disks
Clutch plates
Clutch center
External circlip, 17 mm
Clutch springs

Qty
11111211154114No.
1516171819202122232425262728

Part Name
Clutch lifter plate
Radial ball bearing, 6001
Flange hex bolt, 6x22
Primary drive gear, 18T
Lock washer, 14 mm
Conical spring washer, 14 mm
Lock nut COMP., 14 mm
Oil seal, 6x13x5C-ring, 13 mm
Clutch release arm
Flang bolt, 6x18
Clutch release arm spring
Plain washer, 10 mm
Dowel pins, 8x12‑2‑Qty
11411111
1111
12No.
29303132
33
34
35
3637
38
3940

Part Name
Clutch cable, COMP.
Gear shift arm, COMP.
Collar, 12.2 mm
Gear shift return spring
Gear shift arm spring
Crankcase gasket
Clutch lever assembly
Main shaft, 13T
Counter shaft first gear, 34T
Main shaft third gear, 21T
Counter shaft third gear, 27T
Kick starter pinion, 24T
Instruction Manual

Qty
111
1
1
1111
11
1
1Jul./02/ 07

Installation ProceduresThis Installation Procedures relate to the work at a stage after the engine has already been demounted from theframe. For the work before this stage, please refer to an owner’s or service manual, instruction manual, or engine
tuning master book.

Disassembly:(Please do the following work referring to an owner’s manual & /or aservice manual.)

３．
Using a gear holder, tighten the lock nut to the specified torque withthe crankshaft being seated in detect, and fold back the hook on thelock washer.
Torque: 39 N･m (4.0 kgf･m)※ 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 locknut.

１．Disassemble an engine, and then separate a crankcase.
２． Detach a kick starter spindle, and then a transmission, gear shaft
drum and all.

Assembly:
Transmission assembly※Please refer to an Instruction Manual for a 3-Speed Close Transmission
Gear Kit (Item No. 02-04-254).

Installation of primary drive gear
１．First make sure that a stock collar is in the crankshaft. Then attacha primary drive gear, lock washer, and conical spring washer, which
please fasten with a lock nut for the moment.
※ Be careful about the direction in which to attach the conical spring
washer.

Clutch assembly:
１．To clutch center, attach alternately one each of five friction disks andfour clutch plates, and then a clutch pressure plate.
※ Apply engine oil to both sides of the clutch friction disk.
※ Check that the bumpy surfaces of the clutch center and clutch
friction disk are meshing well with each other.

２． Into a transmission main shaft, put a thrust bearing seat, thrustbearing, thrust washer, and washer in this order, and attach a clutch
outer COMP to the transmission main shaft.
※Set the thrust bearing seat in the location so its protrusion gets stuckon the crankcase, preventing it from rotating※ Apply engine oil to the thrust washer and clutch outer ball bearing.

‑3‑Jul./02/ 07

２．Attach the clutch spacer to the transmission main shaft.

４．Place four clutch springs into the pressure-plate boss, and fix theFitting the protrusion on the clutch friction disk into the groove in theclutch 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.

clutch lifter plate with a flange hex bolt. And tighten it to thespecified torque diagonally in a few steps.
Torque: 12 N･m (1.2 kgf･m)

３．Fit the supplied external circlip to the groove in the main shaft with thecirclip’s round corner on the downside.

Assembly of right crankcase cover and clutch cable※ Don’t expand the circlip more than necessary.
※In case you find it hard to fit the circlip into the mainshaft groove, thendo the work lifting up the main shaft.

※ Please assemble these parts referring to the instruction manual for thedie-cast clutch cover kit.
※ Please assemble the engine referring to the instruction manual for therelative engine.

3-5-16 Nishikiorihigashi Tondabayashi
Osaka Japan
TEL : 81-721-25-1357
FAX : 81-721-24-5059
URL : http://www.takegawa.co.jp‑4‑Jul./02/ 07