Standard Kit for Special Clutch for Die-Cast Cover Instruction Manual(Coming with a kit for 3-speed close transmission gear)

CO・Thank you for purchasing one of our 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.

Item No.：０２−０１−５０９２ (Only for 3-speed transmission)Compatible Models and Frame No.:
XR50R ：AE03-1000001〜
CRF50F ：AE03-1400001〜◎ Please note that the descriptions in this manual like illustrations and photos may differ from the actual hardware.

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.

PY◎ 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‑Oct./15/ 12

Kit Contents

CO３６１８３５１９２０５２１１２３０３

９８

４２２２３６２９３４１１７６３３３２

１２

３１４０PY

１４２４２５３８３９３７No.
Part Name
1 Thrust bearing seat
2 Thrust bearing, 17 mm
3 Thrust washer, 17x30x1
4 Washer, 17x23x0.5
5 Clutch outer COMP., 67T
6 Radial ball bearings, 6803
7 Distance collar
8 Clutch spacer, 17x21.5x3
9 Clutch pressure plate
10 Clutch friction disks
11 Clutch plates
12 Clutch center
13 External circlip, 17 mm
14 Clutch springs
15 Clutch lifter plate
16 Radial ball bearing, 6001
17 Flange hex bolt, 6x22
18 Primary drive gear, 18T
19 Lock washer, 14 mm
20 Conical spring washer, 14 mm
21 Lock nut COMP., 14 mmQty
11111211154
1141141111１７１３２６２７Die-cast cover kit

２８４１１５１６１０２８Repair Part Item No. In packs of22301-181-T00
100-02-0061
100-02-0060
100-02-0097
100-02-0030
100-00-0024
228242-181-T00
123512-GEF-T00
122350-KRL-T00
100-02-0026
500-02-0029
422120-181-T00
100-02-0005
122401-181-T00
422361-GEF-T00
100-00-0021
100-02-0098
423121-181-T01
190431-001-T00
100-02-0036
190200-181-T00
1No.
Part Name
22 Oil seal, 6x13x5
23 C-ring, 13 mm
24 Clutch release arm
25 Flang bolt, 6x18
26 Clutch release arm spring
27 Plain washer, 10 mm
28 Dowel pins, 8x1229 Clutch cable, COMP. 910mm
30 Gear shift arm, ASSY. 181mm
31 Gear shift arm, COMP.
32 Collar, 12.2 mm
33 Gear shift return spring
34 Gear shift arm spring
35 Crankcase gasket
36 Clutch lever assembly
37 Main shaft, 13T
38 Counter shaft first gear, 34T
39 Main shaft third gear, 21T
40 Counter shaft third gear, 27T
41 Kick starter pinion, 24TQty
111
1
11
2
11
11
11
1
1
11
1
1
1Repair Part Item No. In packs of00-02-0037
100-02-0099
122812-181-T00
100-00-0023
122815-165-T00
100-00-0151
100-00-0153
222870-181-T20
100-02-0324

100-01-0096
02-01-028
23211-GCF-T10
23421-GCF-T00
23471-GCF-T10
23481-GCF-T10
28211-GEF-T00

111
1111

※ 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.
‑2‑Oct./15/ 12

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:

３．Using a gear holder, tighten the lock nut to thespecified torque with the crankshaft being
seated in detect, and fold back the hook on thelock washer.

CO(Please do the following work referring to anowner’s manual & /or a service manual.)

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

Assembly:

Transmission assembly

Caution: Apply the specified torque.
Torque: 39 N・m (4.0 kgf・m)

２．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.

※ After tightening the lock nut to the specified
torque, turn the lock nut in the direction oftightening 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.

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

３．Fit the supplied external circlip to the groovein the main shaft with the circlip’s roundcorner on the downside.
※ Don’t expand the circlip more thannecessary.
※In case you find it hard to fit the circlip into
the mainshaft groove, then do the work lifting
up the main shaft.

Installation of primary drive gear

１．First make sure that a stock collar is in thecrankshaft. Then attach a primary drive gear,
lock washer, and conical spring washer,which please fasten with a lock nut for themoment.
※ Be careful about the direction in which toattach the conical spring washer.

PY

Keep the hooks in close contact with the lock nut.

Lock nut
Drive gear

Lock washer
Conical spring washer(Be careful of the direction.)

Fit into the groove.

Turn and tighten the locknut so the hooks fit into thegrooves on the lock nut.

Clutch assembly:

２． Into a transmission main shaft, put a thrustbearing seat, thrust bearing, 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 soits protrusion gets stuck on the crankcase,preventing it from rotating※ Apply engine oil to the thrust washer andclutch outer ball bearing.

１．To clutch center, attach alternately one each of
five friction disks and four clutch plates, andthen 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 wellwith each other.

４．Place four clutch springs into the pressureplate boss, and fix the clutch lifter plate witha flange hex bolt. And tighten it to thespecified torque diagonally in a few steps.
Caution: Apply the specified torque.
Torque: 12 N・m (1.2 kgf・m)

Assembly of right crankcase cover andclutch cable※ Please assemble these parts referring to theinstruction manual for the die-cast clutch coverkit.
※Please assemble the engine referring to theinstruction manual for the relative engine.
Co.,Ltd.
3-5-16 Nishikiorihigashi Tondabayashi Osaka Japan‑3‑TEL : 81-721-25-1357 FAX : 81-721-24-5059 URL : http://www.takegawa.co.jp
Oct./15/ 12

CONotice on installing Special clutch or Dry Clutch

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 different 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.

Genuine collar

Collar included in Takegawa
Heavy-Duty 3 disc clutch kit
step

PY
flat

10mm

8mm

Should be used an genuine one.

Do not use.

※There are two types of Heavy-Duty 3 disc clutch kit.
One uses the included collar and the other one uses
the genuine collar.
Jan./28/ 13

Jan./28/ 13

the genuine collar.
One uses the included collar and the other one uses
※There are two types of Heavy-Duty 3 disc clutch kit.

Do not use.
Should be used an genuine one.
8mm
flat
Genuine collar

10mmCollar included in Takegawa
Heavy-Duty 3 disc clutch kit
step

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 different 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.

Notice on installing Special clutch or Dry Clutch