Friction Disk & Heavy-Duty Spring Set Instruction Manual
Product number 02-01-0816

KSR110Applicable model KLX110
Z125 PRO

Thank you for purchasing one of our products. Please strictly follow the following instructions in installing and using the products.
Before fitting the products, please be sure to check the contents of the kit. Should you have any questions about the products, pleasekindly contact your dealer.
◎ Please note that, in some cases, the illustrations and photos may vary from the actual hardware.

☆ Please read the following instructions carefully before installation ☆
◎ We do not take any responsibility for any accident or damage whatsoever arising from the use of these sets not in conformity withthe instructions in the 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 these sets.
◎ If you make modifications to any product of the sets, we shall be held free from any guarantee of the product.
◎ You are requested not to contact us about the combination of our products with other manufacturers'.
◎ Product may have edges or protrusions. Be sure to wear working gloves.
(Please wear work gloves when working, even if a photo in this article show without work gloves.)◎ In installing these sets, please prepare and strictly follow a genuine service manual for your vehicle. In addtion, you need toprepare gaskets and packings suitable for the specifications of your vehicle.
◎ Always use new gaskets and packings. And check those parts, to be reused, for wear and damage. If you find worn or damaged parts,replace them with new ones.
◎ This kit consists of heavy-duty clutch springs and in larger numbers to be used. Through the installation of these springs, theclutch operation will be heavy.

CO～ Features ～○ As the engine power increases, clutch slips easily. This clutch spring is a set that increases the spring rate from the stock springand changes the springs use from 4 to 6. This prevents clutch slippage of high power engines. (KSR110, KLX110)
CautionThe following show the envisioned possibility of injuries to human bodies or property damage as a result of disregarding
the following cautions.

■ Work only when the engine and muffler are cool. (Otherwise, you will get burned.)■ Do the installation with right tools. (Otherwise, breakage of parts or injuries to you may take place.)■ 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.)■ The product and the frame, might have edges or protrusions. When working, please wear work gloves to protect your hands.
（It may cause injury.）■ Before riding, always check every hardware for slack in parts like screws. If you find slack ones, screw them securely up to thespecified torque.(Otherwise, improper tightening may cause parts to come off.)
Warning

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The following show the envisioned possibility of human death or serious injuries to human bodies as a result ofdisregarding the 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, make sure your motorcycle is secure on level ground 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 replacethem with new ones. (The continued use of these damaged parts as they are could lead to accidents.)■ Keep plastic bags for packing the products out of children's reach, or discard them.
(If children get them on, there will be a danger of their suffocating.)◎ 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.
Product content①②③No.

Part NameQty

1Clutch spring

62
3

Clutch spring bolt, 5x20
Cclutch friction disk

65Repair Part Item No.
02-01-0296(with ② bolt,each 6 pcs)
00-00-0468 (10 pcs)
00-02-0515 (5 pcs)

※ 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.
※ Repair parts may differ slightly from the kit contents in terms of shape, etc.
There is no problem to use it. Please be forewarned.
CONTACT Address：3‑5‑6 Nishikiorihigashi Tondabayashi Osaka JAPANTEL: ＋8‑72‑25‑357 FAX:＋8‑72‑24‑5059 e‑mail:english@takegawa.co.jp URL http:// www.takegawa.co.jp
Please contact with your name and country name provided.（Only English please）
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■ Mounting procedure※ Please refer to the Genuine Service Manual for detailed mounting methods and specified torques that are notspecifically described.

〇 Check the kit contents.

〇 Referring to the photo below, attach the proper springs in theproper number to meet the engine specification, and tighten M5x20
clutch spring bolts diagonally to the specified torque.
※ Be sure to tighten them equally.
※ Use either four or six springs.

〇 Prepare suitable tools for the work.
〇 Make sure your bike is secure on a sidestand.

Caution: Apply the specified torque.
Clutch spring bolt

〇 Remove the clutch cover with referring to the genuine service
manual.
※ In case a primary clutch is installed inside the clutch, remove
it referring to the service manual.

COTorque：3.4N・m（0.35kgf・m）
Clutch spring bolt

For(KSR110/KLX110)〇 Remove clutch spring bolts on the secondary clutch to remove aclutch spring plate and clutch springs.

For 4-spring specification〇 Detach the secondary clutch and split it. And change thefriction disks with provided ones.
※ The friction disks have directional property.
When the friction disks are installed per the photo below, see
to it that the grooves in all disks are in the same direction asshown in the photo.
※ If you are reusing a steel plate, please check it in accordancewith the service manual.
When installing the friction disks, apply engine oil to thesurfaces.

Friction disk

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Stock spring

Kit spring

For 6-spring specification

stock spring

Kit spring

stock spring

Kit spring

Kit spring〇 Install the removed parts by referring to the genuine service
manual.
〇 Before starting the engine, check that the clutch operates
normally, and also check hardware for slack.

※ In case a manual clutch kit is installed, the lever
operation will become heavy, and in case a centrifugal
clutch kit is installed, the shift change will becomeheavy.
※ If you feel the lever operation or shift change heavy,
we advise you to install the genuine and our springs
alternately and adjust the clutch pressure to meet yourengine specification.

◎ You can see this instruction manual on our website as PDF data .
If this document hard to read, please download it from our website.
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