5-Speed Transmission Instruction Manual
Contents
1. N 5 Speed Transmission Instruction Manual Item No 0 00 00 00 L0 L O Thank you for purchasing one of our products Please strictly follow the instructions to install and Applicable models and frame No use the products O Before installing the products please be sure to check the contents of the kit If you have any KSR110 A3 KL110A A045011 questions about the products please kindly contact your local TAKEGAWA dealer KLX110 A4 LX110A A23003 From 05 models onward Please note Illustrations and photos may vary from actual hardware Read all instructions first before starting the installation O This kit is for exclusive use in KSR110 amp KLX110 Please note that the kit cannot be installed on any other models of motorcycles Installation of this kit requires engine removal mounting and crankcase splitting At some stages of the installation some special tools are required Besides 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 not skilled or do not have sufficient knowledge may not be able to install the kit correctly O This instruction manual covers the installation work only after the procedures of the engine removal from the body disassembly of a cylinder head cylinder piston clutch cover flywheel generator cover and primary and scondary clutch assemblies and the splitting of the crankcase Ple2. 3 5 16 Nishikiorihigashi Tondabayashi Osaka Japan TEL 81 721 25 13857 FAX 81 721 24 5059 URL http www takegawa co jp le O O O Set the change shaft arm to the holder p p Dec 15 10 a X Rasp Type of Cutter Process Standard Diameter when measured with bearings in the middle Where to process Shaded portion Caution Remark Take note that this machining leaves a hole on the spot for mounting a lower Diameter these porsions to make them Imm 0 039in lower Depth should be measured from this point N Crankcase Machining Flat end mill or blue nosed end mill under D Depth when measured with crank case s mating surface in the middle Cover the bearings with a masking to prevent chips and shavings from falling into them neutral switch Machining Sizes Counter shaft side Main shaft side 67mm 2 638in with ball bearings 45mm 1 772in with needle bearings in the middle in the middle 48mm 1 890in from crankcase s Depth 38mm 1 496in from crenkcase s mating surface p mating surface Left side crankcase JO Vi A hole will be left on this threaded portion SPECIAL PARTS WNAE NYA P Dec 15 10 Transmission gear assembly drawing Main shaft M5 gear 211 Ma
3. In this case please order them with the set number Here 0 Installation Instructions O O Process a left side crankcase as per the O0 O Prepare a suitable stand to place a instructions Please see the machining crankcase on drawing of the crankcase Put a stock locating pin into a gear shift drum and fit the drum into the right side crankcase In case it s hard to put in the pin insert it with a plastic hammer gt _ 7 Ey Locating pin we E K Se gt gt N Left side case te 0 O Detaching the drive shaft bearings retainer from the right side crankcase install the one included in the Kit k Install the washer with the flat surface toward the bearings Torque 10 N m 1 0 kgf m iy Change the spring with a provided spring Aligning a hole on the shift drum cam with the locating pin on the drum fix a cam Install dowel pin with face down taper side Dowel pins Position lever spring Le Tapered F Dec 15 10 Place a holder and tighten up a cap bolt O O Apply engine oil to pawls on each shift fork O O Detach a stock kick gear from the kick Apply screw locking agent to the cap bolt Torque 6 N m 0 6 kgf m Cap bolt N f i f 7 a Y a ss Set the shift drum at a NEUTRAL position Drum
4. into a hole on the right side crankcase x Please note that the kick starter cannot be fixed after joining together the crankcases O0 0 Remove dirt and dust remaining on the mating surfaces of the right and left side crankcases and degrease the mating surfaces Apply liquid packing to the mating surface of the left side crankcase Recommended sealant KAWASAKI Bond silver color liquid gasket 92104 002 x Do not apply liquid packing to the portion A as shown in the figure below ae Dec 15 10 O O Fix two locating pins and O ring to the O0 O O Invert the crankcase O0 O O Detach a shift arm spring from a stock crankcase Attach a stock spacer to the mainshaft And attach the processed left crankcase and join a right and left crankcases together by hitting them with a plastic hammer X Align the tip Q of the kick shaft with a kick shaft hole on the left crankcase and fix the cases Locating pins O ring l Stock spacer Fix screws on the crankcase and screw them up in the numerical order Torque 6 N j m 0 6 kgf m x Apply screw locking agent to the screw No 10 X Wipe off the liquid packing that will squeeze out O O Attach a spring and pin to the shift drum Attach an O ring to a neutral switch and attach the switch to the case Apply liquid packing to the lower screw
5. Important Notice from TAKEGAWA Though we have developed and designed each tuning up part to have a certain level of strength and durability the wrong use or handling of them will most likely increase the fear of parts breakage Therefore you are kindly requested to use these parts with great care as special parts not as stock parts Features This is a kit for 5 speed transmission with a gear ratio for sport driving as compared with a standard 4 speed transmission Docks of each gear are tapered to prevent the gear from coming out A wide range of settings will be available when this kit is used in combination with a final gear Also available 5sp to 6sp conversion kit 02 04 0078 Stock speed transmission on KSRIIO TAKEGAWAS close 5 speed transmission 1086 25723 EN C7 L181 26 22 Ce gee 525 ele Dec 15 10 Kit includes wo Part Name Jo Repair Part Tiem No Please see the Transmission Gear Assembly Drawing on the last page of this Manual 2430 KLIT 24AT KUITI 00 02 0049 6 Thrust washer Imm a 00 02 0073 2821r KLIT e Change shaft lever COMP o a peoo o Change shat rem spn a asao SS 24213 KLT TOO E E feere gear sitok O O a oos Cis Reum sping bot o oao S Cia shit for shat O OOo o a y o x Please order repair parts with the Repair Part Item No Without the repair part item NO we may not be able to accept your orders Some parts are only available as a set
6. ase do the removal work referring to KAWASAK s service manual for KSR110 KLX110 for the removal procedures before this stage O Gaskets O rings and packings must be replaced with new ones at the time of disassembly Since this kit does not include gaskets O rings packings etc which are necessary for engine disassembly please purchase these gaskets O rings packings etc separately O This kit is applicable to 05 models onwards In case this kit will be installed on 04 or earlier models you are requested to purchase a KAWASAK s genuine change lever for 05 onward models You are discouraged from using this kit on a motorcycle of 138cc or 178cc engine displacement We recommend that the kit be used on a motorcycle of less than 125cc engine displacement When you use this kit on a motorcycle of 138cc or 178cc displacement it is understood that you do so on your own responsibility which please note 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 Special instruction for Thailand made KSR110 KL110CBF Vin JKAKL110CCDA00058 and up To make smooth gearshift please replace following parts at the same time Kawasaki genuine parts 14014 1118 plate position 13236 1256 lever comp AN The following show the envisioned possibility of i
7. cam Position roller O O Invert the crankcase After applying grease to a provided 12mm thrust washer attach it to the countershaift After putting together a mainshaft assembly and countershaft assembly fit them into the right side crankcase at a time x Take care to prevent a thrust washer from coming off x Apply engine oil to every gear and bearing Mainshaft and fit the forks into grooves on each gear Change speed pull rod Left fork amp Center fork Right fork x Pay attention to the location of each fork Apply engine oil to the supplied shift rod and put the rod through shift forks sliding each shift fork And install this unit onto the case 14 5 TAKEGAWA KL1 L stamped here AS I Left gear shift fork 18 e A Ja NA Center gear shift fork 18 l LN H AF Right gear shift fork Genuine parts starter And apply engine oil to a kick gear of the kit and fix it Apply grease to a stock washer and fix it to the tip of a kick shaft Kick starter Washer lt Put the kick starter
8. in shaft M2 gear 16T i Ge 8 0 OOUOU 7100 000 M1 gear 131 M3 4 gear 19T 21T 0000000 0 00 D 00000 0 00 00 D Spacer Stock F SFr amp Spline washer 17mm dee 1 OO Extemal circlips 17mm 00 00 0 000 Counter shaft C5 gear 261 Thrust washer B 17MM shift clutch 000000000000 0 0 0 0 0 00 N 0080 0 00 0 00 C1 gear 35T C4 gear 28T C3 gear 3011 C2 gear 321 0000000000 D 0000000 0 00 D 0000H 0 0 00 0 0000 0 0 0 0 0 0 0 i oe el Counter shaft Re Thrust washer 12mm Cf i 00 00 0 0 0 ant Extemal circlips 17mm Extemal circlips 17mm OHO O0 U000 I a GL Spline washers 17mm 00 00 0 000 Thrust washer S 17mm HO 00 0000 Spline washer 17mm Oo a 000 Part Nae Oy Repair Part teem No m packs oF Spline washers l mm 4 00 02 0023 Thrust washer S 17mm 00 02 0024 Extemal circlios 17mm 00 02 0005 Thrust washer B 17mm 00 02 0056 Thrust washer 12mm 00 02 0073 iL 2 4 SPECIAL PARTS WNKSeV W Ge Dec 15 10
9. njuries to human bodies and property damage as a result of disregarding the CAUTION following cautions O Before starting the installation make sure the engine and muffler are cool at below 35 degrees Celsius Otherwise you will burn you O Do the installation with right tools 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 O Do not use or process other parts than those included in the kit or specified parts Otherwise the breakage of parts is highly likely to follow O The installation of this kit will change the gear change pattern to the return system of 1 down 4 up Change gears infallibly only after you have completely disengaged the clutch Changing gears forcibly or without disengaging the clutch on the manual gear shift motorcycle will cause the gears and other parts to get damaged O Before riding check every hardware like screws and nuts for slack and for abnormal sound When you notice something abnormal with your motorcycle while riding down a road immediately stop riding and check what went wrong with the motorcycle Please be informed that mainly because of improvement in performance design changes and cost increase the product specifications and rices are subject to change without prior notice No return accepted after installation This manual should be retained for future reference
10. s and tighten two screws Torque 3 N m 0 3 kgf m Xx As a hole will be made after processing of the crankcase never fail to apply liquid packing to the screws at the lower part If no liquid packing is applied this will cause the engine oil leakages Neutral switch Liquid packing applied here Put a return spring tip into a hole on the kick shaft and rotate the spring clockwise Put the other spring tip into a hole on the crankcase Attach a plastic spring guide X Check that the crankshaft mainshaft and countershaft rotate smoothly Xx While rotating the countershaft rotate the shift drum and check if the gear shifts to each position ig PA Kick starter Guide Return spring O0 O O Remove the return spring bolt in the R crankcase Apply screw locking agents to kit s bolt and tighten it Torque 22N m 2 2kgf m O0 O O Install kits change shaft return spring to the case and the bolt change shaft lever which please fix to a provided change shaft lever Shift arm spring Change shaft lever OO Insert kits change shaft into the position as illustrated in the picture below x You cannot insert it into the center because the bolt and the protrusion will interfere and insert the protrusion of the change shaft into the return spting O E O Referring to the service manual reinstall back the removed hardware SPECIAL PARTS Co Ltd
Download Pdf Manuals
Related Search