background image

COPY

2020.11.4

3/4

02-01-0404,0405,0408,0409

● 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 the   
 thermostat 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.

Safety Precautions for Use

● Disassembly

1.Make sure the bike is secure on a sidestand.
 Prepare an oil container, and detach a 
 drain plug to drain the engine oil.
2.Remove a kick pedal, right step-holder, 
 and brake pedal.
 Unfasten a screw on the clutch cover to 
 remove the clutch cover, cover gasket and 
 dowel pin.
3.Remove a release lever, release ball, release 
 cam, ball bearing and bearing holder.
 a. Release ball assembly
 b. Release cam
 c. Ball bearing
 d. Ball bearing holder
 e. Release lever
 ○ Except KSR PRO (KL110EEF)

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.

a

b

c

d

e

Change-shaft return spring

Change shaft

● About primary clutch gear:

 If the clutch gear is installed , there 
 will be no backlash, and the noise from 
 the 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  a 
 clutch holder, clutch holder spring, ring 
 and 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

Clutch holder

Primary-clutch housing

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 it 
 with a bolt.

  Caution: Apply the specified torque.
Bolt

 Torque:11.8N・m(1.2kgf・m)

☆ If  you  want  to  use  to  KSR  PRO(KL110EEF) 
 (following KSR PRO), or if it is 
 purchased 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 accordance 
 with an instruction of 5-9 of the 
 mounting procedure.
☆ When installing only in the clutch cover 
 kit, to perform installation work in 
 accordance 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 to 
 the 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 the 
 secondary clutch.
※ At this point, check that the marks on the 
 cog tips are not meshing with each other.
※ In case the clutch gear is not to be 
 installed, the work above is not needed.
 Tighten  a  14mm  nut,  holding  a  secondary 
 clutch with a clutch holder.

 Tighten a 14mm nut, holding the primary 
 drive gear.

8.Remove a bolt for engine ground wire on 
 the crankcase.
 (This is applicable only to KSR110)

7.Remove a change pedal to pull out a 
 change-shaft lever.
 Remove a change-shaft return spring from 
 the change-shaft lever.

Bolt for earth wire

● Assembly and installation:

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

  Caution: Apply the specified torque.
Nut 14mm

 Torque:72N・m(7.3kgf・m)

  Caution: Apply the specified torque.
Nut 14mm

 Torque:72N・m(7.3kgf・m)

○ 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

Отзывы: