Spcial Clutch Cover Kit (Wire-System) Instruction Manual
KSR11002-01-0404(with drive gear)
02-01-0405(without drive gear)
Product number
KLX110(DR-Z110)
02-01-0408(with drive gear)
02-01-0409(without drive gear)

KSR110 ('03 ～ )/ KL110A-000001 ～/ KL110A-A02833 ～KSR110 (KL110CBF) / JKAKL110CCDA00058 ～Applicable model
KSR110 (KL110DDF) / KL110D-A57002 ～KLX110 ('03 ～ )/ LX110A-A08133 ～KLX110L/ LX110D-A72046 ～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.
☆ Read all instructions first before starting the installation. ☆

CO

Please use a thermo unit of Item No. 02-01-5052 (coming with a gold cap) for use with this clutch cover.
◎ 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 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 otherproducts than this one after the installation and use of this product.
◎ As brake arms and mufflers, made by other manufacturers, may interfere with the clutch cover or clutch cable. So please do not use
these brake arms and mufflers.
◎ You are 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 fitting models and frame numbers only and that it
cannot be mounted on any other models.
◎ Installation of this kit requires the disassembly and assembly of the clutch, and other work. Moreover, the use of genuine special tools is
specified in installing some parts. Do the installation work properly referring to a instruction manual for the relevant motorcycle models.
◎ Please consult with your motor cycle dealer for KAWASAKI about their service manual or special tools.
◎ KSR110(KL110CBF / KL110DDF), if be mounted on KSR PRO(KL110EEF), the included clutch lever ASSY. interfere with genuine control housing.
However, there is no hindrance to operation.
In the case of use in KSR PRO (KL110EEF), it does not interfere when using genuine clutch lever.
If using in KSR110 (KL110CBF / KL110DDF), use of KSR PRO (KL110EEF) for genuine clutch lever also possible.
Genuine products number：46076-0091 LEVER-ASSY-GRIP,CLUTCH◎ This product is impossible attach to KSR PRO (KL110EEF) JKAKL110EEDA88121 ～ , it becomes possible to mounting you can purchase ourquick shift kit.
～ Features ～PY● This is a kit to convert a stock automatic centrifugal clutch to a manual wire-type clutch.
● The clutch cover is made of Die-cast aluminum, buffed and coated clear paint.
● You can deliver the oil into the oil cooler from the clutch cover, and the optional of thermostat can be installed.
● To the oil hole, a stock filler cap or an optional breather cap can be installed.
● The rack-and-pinion systems in the clutch operating mechanism, leading to improved clutch operationality.
● This kit is installable on both stock clutch or optional heavy-duty 6-disk clutch kit.
● With the optional hydraulic cylinder kit, the clutch operation can be converted from the wire-system to hydraulic system.
● Removal of a stock primary clutch and use of a special drive gear will reduce the load on the crankshaft and improve the throttle
response.
● This kit comes with a quick-release type clutch lever which can be installed or detached with a bolt only. Moreover, for installation
on KSR110, an M8 mirror holder is additionally included in this kit.
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.)■ 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 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

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 motorcycle 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.)■ 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 high risk of explosion, work in a well-ventilated place. (Otherwise it may cause a fire.)◎ 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.
CONTACT Address：3‑5‑16 Nishikiorihigashi Tondabayashi Osaka JAPANTEL: ＋81‑721‑25‑1357 FAX:＋81‑721‑24‑5059 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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Product content

31

32

28

29
32

25

32
34
33

26
32

32

32

32

32

CO
16

23

30

24

22

17
18

1

20

21

5

13

10
14

15

3

12

4

9
6

8

7

PY
19

7

29

6

32

31

32

2

32

11

32

32

27

32

32

32

No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

Part Name
Right crankcase cover assembly
Oil pot window kit
Clutch release pinion
Clutch release rack
Flat head screw, 4x10
Oil plug bolt, M10x1.25
Sealing washer, 10 mm
Thermostat hole cap (silver)
O-ring, 15 mm
Oil seal, 10x17x5
Oil seal, 16x26x7
Oil sea, 12x20x5
Internal circlip, 22 mm
Hole cap
O-ring, 30 mm
Clutch release arm
Clutch arm spring

18 Plain washer, 10 mm

Qty
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1

Repair Part Item No.
00-02-0389
00-02-0031
00-02-0033
00-02-0039
00-00-0100 (10 pcs)
00-07-0072 (with washer)
00-07-0106 (10 pcs)
00-07-0063 (with O-ring)
00-00-0185 (5 pcs)
00-02-0006
00-01-0039
00-01-0038 (2 pcs)
00-02-0115 (3 pcs)
09-06-0131 (with O-ring)
00-01-0034 (4 pcs)
00-02-0106
00-00-1674

100-00-0151 (10 pcs)

No.
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34

Part Name
Clutch cable receiver
Clutch lift rod
Shim ring, 9.5x20x 0.5
Change-shaft return spring
Primary drive gear, 22T
Clutch cover gasket
Clutch lever assembly
Clutch leverHex wrench, 5 mm
Clutch cable COMP., 910 mm (KSR110)
Clutch cable COMP., 850 mm (KLX110)
Socket cap screw, 6x15
Socket cap screw, 6x20
Socket cap screw, 6x25
Socket cap screw, 6x35
Mirror bracket, 8 mm
Mirror bracket, 10 mm

Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
8
1
1

Repair Part Item No.
00-00-2104
00-00-1682
00-02-0116
00-02-0153
02-01-0304
00-02-0417
02-01-0601
00-00-2193
00-02-0107
00-02-0133
00-00-0718 (5 pcs)
00-00-0721 (5 pcs)
00-00-0722 (5 pcs)
00-00-0724 (5 pcs)
00-00-1695
00-02-0420※ 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.
Some parts are only available as a set. In this case, please order them with the set number.
※ In Item Nos of 02-01-0408 and -0409 is the length of the part number 28 is 850 mm.
※ In Item Nos of 02-01-0408 and -0409 is not included No. 33 and No. 34 listed above.
※ In Item Nos of 02-01-0405 and -0409 is not included No. 23 listed above.

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Safety Precautions for Use● This clutch cover does not operate. Without a special primary drive gear.
● The optional thermostat is usable only when an oil-cooler hose is connected to the crankcase cover. Never install the thermostat
when an oil cooler is not installed, or when the oil-cooler hose is connected to any other hardware than the crankcase cover.
● When the oil-cooler hose is to be connected from the crankcase cover, be sure to either install the thermostat or when thethermostat is not to be installed, install a oil hole plug included in the Oil Cooler Kit. (*If the above hardware is not installed,
the engine oil will not circulate around the oil cooler.)● NEVER install a thermostat or an oil plug bolt if you connect an oil cooler hose to either the oil filter or cylinder-head oil pipe.
Otherwise, the engine oil will not be provided to the crankshaft, damaging the engine.
● If the oil-cooler hose is connected to the crankcase cover, only the engine oil, to be provided to the crankshaft, will circulate
to the oil cooler, and engine oil, to be provided to cylinder head, will not circulate to the oil cooler. In order to send entire
amount of engine oil to oil cooler, either connect the oil hose to the oil filter, or install oil cooler onto either crankcase or
cylinder-head oil pipe.
○ When mounted on KSR110(KL110CBF/KL110DDF) and KSR PRO(KL110EEF), the clutch lever(included in the kit)may interferes with the stock
control housing.
No problem in operation. Please be forewarned.
Stock clutch lever will not interference when using with KSR PRO (KL110EEF)
For KSR110 (KL110CBF/KL110DDF):The stock clutch lever of KSR PRO(KL110EEF)will not interference.
Genuine No.：46076-0091 LEVER-ASSY-GRIP,CLUCH

CO■ Mounting procedure※ With regard to the mounting method and the specified torque of detail, refer to the genuine service manual.

● Disassembly

1.Make sure the bike is secure on a sidestand.
Prepare an oil container, and detach adrain plug to drain the engine oil.
2.Remove a kick pedal, right step-holder,and brake pedal.
Unfasten a screw on the clutch cover toremove the clutch cover, cover gasket anddowel pin.
3.Remove a release lever, release ball, releasecam, ball bearing and bearing holder.
a. Release ball assemblyb. Release camc. Ball bearingd. Ball bearing holder
e. Release lever○ Except KSR PRO (KL110EEF)

a

b

c

d

e

7.Remove a change pedal to pull out achange-shaft lever.
Remove a change-shaft return spring fromthe change-shaft lever.
Bolt for earth wire

Change-shaft return spring

1.Attach a provided change-shaft return
spring, which please install onto the
crankcase.
※ Be careful the direction of the return
spring.
Attach the change pedal, and tighten itwith a bolt.
Caution: Apply the specified torque.
Bolt

Torque：11.8N・m（1.2kgf・m）

PY
Change shaft

8.Remove a bolt for engine ground wire on
the crankcase.
(This is applicable only to KSR110)● About primary clutch gear:

4.Remove a 14mm nut, holding a primary
clutch with a special tool of primary
clutch holder.
KAWASAKI genuine special tool:
Primary clutch holder: 57001-1507
5.Remove a 14mm nut, holding a secondary
clutch with a special tool of clutch
holder.
※ Install the special tool of clutch holder,meshing three convex portions on the
clutch holder with a concave portion on
the clutch hub.
KAWASAKI genuine special tool:
Clutch holder: 57001-1508
6.Remove the primary and secondary clutches
together.

● Assembly and installation:

If the clutch gear is installed , there
will be no backlash, and the noise fromthe gear will be reduced.
Without installation of the clutch gear
does not affect the clutch operation.
(Install the clutch gear only when the
kit comes with a gear.)
1.From the primary clutch housing, detach aclutch holder, clutch holder spring, ringand clutch gear.
2.Attach a clutch gear and ring to a provided
drive gear.
Attach a holder spring to the clutch holder.
Press the holder into the drive gear,
meshing the cogs correctly.
Put marks on any random tips of cogs meshing
together.
Clutch gear
Ring
Clutch holder spring☆ If you want to use to KSR PRO(KL110EEF)(following KSR PRO), or if it ispurchased in special clutch kit, attach
the quick shift in accordance with
instructions of 1-4 of quick shift kit
installation procedure.
☆ If purchased in KSR PRO or special
clutch kit, strengthen clutch kit attach
the strengthening clutch in accordancewith an instruction of 5-9 of themounting procedure.
☆ When installing only in the clutch coverkit, to perform installation work inaccordance with previous mounting
procedure 2 to instructions.
If you purchased in KSR PRO or special
clutch kit,to perform installation work
according to the instruction of mounting
procedure 3.
2.In case the clutch gear is installed tothe drive gear, give the clutch gear a
2-tooth clockwise turn. And install the
clutch gear together with the drive gear,
meshing the clutch gear with thesecondary clutch.
※ At this point, check that the marks on thecog tips are not meshing with each other.
※ In case the clutch gear is not to beinstalled, the work above is not needed.
Tighten a 14mm nut, holding a secondary
clutch with a clutch holder.
Caution: Apply the specified torque.
Nut 14mm

Clutch holder

Torque：72N・m（7.3kgf・m）
Primary-clutch housing

Tighten a 14mm nut, holding the primary
drive gear.
Caution: Apply the specified torque.
Nut 14mm

Torque：72N・m（7.3kgf・m）
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3.Attach to spring plate the removed ballbearing holder, and ball bearing, andattach a provided clutch lift rod to theball bearing.
Attach a provided shim ring to thechange-shaft.

6.Attach a bracket to the provided clutch
lever, and spring pin with a plastic hammer.
※ If using in KSR110, please remove genuine
mirror bracket.
※ If you are installing a rearview mirror in
KSR110, it is used in assembling theincluded mirror bracket to the clutch
master cylinder ASSY.
※ For vehicles of KSR PRO(KL110EEF), theincluded clutch lever ASSY is not used, it
is recommended the clutch lever use of
genuine.

Lift rod
Shim ring

Spring pin

4.Degrease the clutch-cover mounting
surface of the crankcase.
Put in two dowel pins into the crankcase,and attach a new clutch cover gasket.
Attach a right crankcase cover, andfasten it with a provided socket cap
screw in a few steps in the order as
specified below.

CO※ Check that a clutch release rack is
attached inside the cover.
※ Attach the right crankcase cover withcare not to damage an O-ring of a kickshaft.
※ And jointly fasten a clutch cable
receiver and the O-ring in place.
※ Fasten an ground cord and the cable
receiver.
(This applies only to KSR110.)②

Fasten ground cord.
(KSR110)⑩⑤Mirror bracket

7.Attach a clutch lever to the steering
handle, and tighten the bolt.

8.Attach a clutch cable adjuster to therelease arm.
Detach a nut on the clutch cable adjustercompletely from the screw, and pass acable through the clutch cable receiver.
Reinstall the removed nut, and fasten the cable
receiver in be tween nuts loosely initially.
Route the clutch cable to the clutch lever
without stretching it by force, and attach
the cable end to the lever Adjust the free （When not installing the thermostat unit）
play at the clutch lever with an adjuster
Remove the thermostat hole cap, attachon the clutch cable, and fasten thenut.
the oil hole plug (included in our oilcooler kit), and tighten to the specified
Caution: Apply the specified torque.
Nuttorque.

PY

Free play at the lever tip: 10 ～ 20 mm※ Fine-tune the free play with the adjusteron the clutch lever⑧

9.Install the removed right step holder,brake pedal and kick pedal.
Caution: Apply the specified torque.
Right step-holder bolt

Torque：26N・m（2.7kgf・m）
Brake-pedal bolt⑥①

Torque：8.8N・m（0.9kgf・m）④

5.Put a 10 mm washer into the release pinion
with the washer’s round edge facing downwards.
Hang one end of a clutch arm spring on therelease arm, and the other end on the cover.
And position the release arm in place as
per the figure below.
※ Turn the release pinion clockwise until
it comes to a halt, and attach therelease arm.
about

1.Install the thermo unit according to theInstruction Manual.
2.Detach two oil plug bolts, attach hardware
like a banjo to match the kind of hose to
be used, and connect the hose.
※ Please see an Operation Manual for thethermo unit.
※ Please see an Operation Manual for theoil cooler kit.
Thermostat unit oroil drain plug hole

Torque：11.8N・m（1.2kgf・m）⑦⑨

Please be sure to use a thermo unit of
Item No.02-01-5052 coming with a gold cap.
Please note that a thermo unit of Item No.
02-01-5053 coming with a blue cap is not
usable(because of different screw diameter).

Torque：8.8N・m（0.9kgf・m）

Torque：8.8N・m（0.9kgf・m）③(In the case of installing the thermo unit)

Caution: Apply the specified torque.
Bolt

Caution: Apply the specified torque.
Socket cap screw

Fasten cable receiver.

Important Notice
Installation of oil cooler:

15°

Kick-pedal bolt

Torque：11.8N・m（1.2kgf・m）
Kick-pedal bolt

Brake-pedal bolt

Step-holder bolt

Caution: Apply the specified torque.
Thermostat hole cap

Torque：13N・m（1.3kgf・m）

Caution:When connecting an oil hose to theclutch cover, you must install athermostat or an oil hole plug.
Without thermostat or an oil holeplug installed,
oil will not circulate and theengine may be damaged.

(In the case of connecting the oil hoseto other hardware than the clutch cover)
NEVER install a thermostat or an oil holeplug if you connect an oil hose to theoil filter or cylinder-head oil pipe.
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 theengine is damaged due to the oil
passage blockage.

10.Fasten a drain plug, and add engine oil.
Caution: Apply the specified torque.
Drain plug

Torque：29N・m（3.0kgf・m）
Release arm
Arm spring

Attach a socket cap screw to the releasearm. And pressing down the release arm
lightly, tighten the socket cap screw.

※ In case a gasket on the drain plug always,
replace it with a new one.
Engine oil level: 0.9 liter (at the time of oilchange)※ Use the following figure just as a guideline on
how to read the oil level through oil pot window.

0.9L
0.8L
0.7L

Caution: Apply the specified torque.
Socket cap screw

Torque：8.8N・m（0.9kgf・m）
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In case an oil cooler is notinstalled:
NEVER install a thermo unit or an oilhole 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 theengine is damaged because the oil
passage will be blocked when thethermo unit or an oil hole plug isinstalled.