Instruction Manual for 6
Contents
1. O ia D ol ne d O ipe NT Right side fork 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 into a hole on the right side crankcase Xx Please note that the kick starter cannot be fixed after joining together the crankcases O0 O 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 Mar 06 07 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 Align the tipQ of the kick shaft with a kick shaft hole on the left crankcase and fix the cases Locating pins ea See Sy Stock spacer Fix screws on the crankcase and screw them up in the numerical order Torque 6 NI m 0 6 kgf m Apply screw locking agent to the screw No2. N Instruction Manual for 6 Speed Transmission Kit tem No 0000 00 0000 Application KSR110 Frame Nos KL110A 000001 A1 A2 Up to 04 models Read all instructions first before starting the installation Thank you for purchasing one of our TAKEGAWA made products Please read the following instructions before installation O 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 O This kit is for exclusive use in KSR110 Please note that the kit cannot be installed on any other types of motorcycles O 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 service manual is prepared for those who have acquired basic skill and knowledge Therefore those who are not sklled or do not have sufficient knowledge may not be able to install the kit correctly 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 Please do the removal work referring to a KAWASAKI s service manual for KSR110 for the removal procedures before this stage O Be sure to re
3. 00 M1 gear 13171 M3 4 gear 19T 21 Main shaft M2 gear 161 ooooo loo coo COU U USALE 00000 000000 Spacer Stock A R ees U Ur SS FAS ZAG a Ball bearing 6803 Spline washer 17mm Special washer 17mm Extemal circlips 17mm Counter shaft C5 gear 26T Thrust washer 17mm C6 gear 25T at ee UO A gi TESE ieee 1 00 mood C1 gear 3510 C4 gear 281 C3 gear 307 C2 gear 3210 000000000 U N 0000 00 UU oo000 4D m 00000000 L0 Counter shaft N des fe gt oOoooo ooo0 o00 T 7 i Thrust washer 12mm i J HEU TT tc T IN uR ear 4q ga Spline washer 17mm Extemal circlips 17mm Extemal circlips 17mm Spline washers 17mm Part Name Qy Repair Part ttem No 1 packs oF pine washers Timm 4 am 5o eemal crips Imm 6 239 5 pecial washer T7mm Thrust washer Tamm SPECIAL PARTS UNEC NVA p Mrr 06 07
4. O The installation of this kit will change the gear change pattern to the return system of 1 down 5 up Change gears infallibly and only after you have completely disengaged the clutch Changing gears forcibly or without disengaging the clutch on the manual gearshift 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 prices are subject to change without prior notice 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 6 speed transmission with a gear ratio for sport driving as compared with a standard 4 speed transmission A wide range of settings will be available when this kit is used in combination with a final gear Docks of each gear are tapered to prevent the gear from coming out Stock 4 speed transmission on KSR110 TAKEGAWA
5. 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 screws and tighten two screws Torque 3 NO m 0 3 kgf m As a hole will be made after processing of packing to the screws at the lower part If no liquid packing is applied this will cause the engine oil leakages a Q y S3 Neutral switch A __ Liquid packing AOS f f of Shift arm spring O0 O O Attach the change shaft lever to the the crankcase never fail to apply liquid O0 O O Referring to the service manual reinstall back the removed hardware O O Fix two locating pins and O ring to the O O Invert the crankcase 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 Kick starter vid Pa Return spring O0 OO Detach a shift arm spring from a stock change shaft lever which please fix toa provided change shaft lever Attach
6. a provided change shaft return spring to the change shaft lever Change shaft return spring Change shaft lever crankcase SPECIAL PARTS WwN4Sey W 3 5 16 Nishikiorihigashi Tondabayashi Osaka Japan TEL 81 721 25 1357 FAX 81 721 24 5059 j URL http www takegawa co jp oA Mar 06 07 la Counter shaft side Main shaft side 67mm 2 638in with ball bearings 48mm 1 890in from crankcase s 38mm 1 496iIn from crenkcase s Rasp these porsions to make them Imm 0 039in lower Depth should be measured from 7 N Crankcase Machining Flat end mill or blue nosed end mill under Process Standard Diameter when measured with bearings in the middle Type of Cutter Depth when measured with crank case s mating surface in the middle Where to process Shaded portion Caution Cover the bearings with a masking to prevent chips and shavings from falling into them Remark Take note that this machining leaves a hole on the spot for mounting a lower neutral switch Machining Sizes 45mm 1 772in with needle bearings ia riddle Plaine in the middle mating surface Left side crankcase Wi this point A hole will be left on this threaded portion SPECIAL PARTS UNLEY NVA r Mrr 06 07 Transmission gear assembly drawing D Main shaft M5 gear 221 M6 gear comp 23T OOUUU0U0 O00 O000 EU 0 Pe Bi
7. d to put in the pin insert it by hitting it with a plastic hammer cam with its tapered portion pointing down Drum cam pins Locating pin wo Tapered portion Los Mar 06 07 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 Set the shift drum at a NEUTRAL position Drum cam Position roller 0 O Invert the crankcase After applying grease to a provided 12mm thrust washer attach it to the countershaift And 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 Countershaft and fit the forks into grooves on each gear Change speed pull rod ry Left side fork i i uy Ic Center fork Right side fork Pa 3 T a x Pay attention to the location of each fork Apply engine oil to a change speed pull rod and moving each shift fork put in the rod to attach it to a case
8. place gasket O ring packing and others with news ones at the time of disassembly In this kit are not included gasket O ring and others necessary for engine disasembly So please purchase them separately O This kit is designed to be applicable to KSR110 of up to 04 models For installation on KSR110 from 05 models and onward please purchase a KAWASAKI made genuine change lever for 04 motorcycle models 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 Machining of a left side crankcase is needed for the installation of this kit Please contact a machining workshop for this processing with the processing drawing The following show the envisioned possibility of injuries to human bodies and property damage as a result of disregarding the 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
9. s close 6 speed transmission 3 000 36 12 2 692 35 13 1 937 31 16 2 000 32 16 1 350 27 20 1 578 30 19 1086 257320 Soa ooo 1181 267221 0o Ee 1086 25 23 J ce Nar 06 07 a Kit includes No Part Name y Repair Part Item No Please see the Transmission Gear Assembly sss Drawing on the last page of this Manual Las 24301 KLI T00 Ca shite drum cam 1 a 24142 6 Thrust washer 12mm 1 _ BW 0I 0023 28211 KLI T00 8 Change shaft lever COMP 1 24610 KL1 T01 9 Change shaft reum spring 1 _ 24651 KLT T00 P10 let shit fork ST peaa a O O iT Cental shit fore a e T T iz Position lever spring 2 S 1 Please order repair parts by indicating the Repair Part Item No as listed above As you see from the list depending on the repair parts in some cases we may not be in a position to accept your order for a single item in the quantity of one Installation Instructions O O Process a left side crankcase as per the O O Prepare a suitable stand to place a Change the spring with a provided spring instructions Please see the machining crankcase on Aligning a hole on the shift drum cam with drawing of the crankcase Put a stock locating pin into a gear shift drum the locating pin on the drum fix a cam and fit the drum into the right side crankcase Put five shift drum cam pins into the drum In case it s har
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