Magnesium Clutch Cover Kit Instruction Manual Item No. (Brown) Applied to Ape50 Ape50 (FI) Ape50 (FI Type D) AC18-1000001 Ape100 Ape100 Type D XR50 Motard XR100 Motard Frame Nos AC16-1000001 AC16-1600001 HC07-1000001 HC13-1000001 AD14-1000001 HD13-1000001 Thank you for purchasing one of our TAKEGAWA s 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, please kindly contact your dealer. Please note that, in some cases, the illustrations and photos may vary from the actual hardware. Please read following instructions before installation. We do not take any responsibility for any accident or damage whatsoever arising from the use of the products 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 other products than this one after the installation and use of this product. This product is designed for exclusive use in the above-mentioned type of motorcycle and frame numbers only. Please take note that this product cannot be mounted on other types of motorcycles. You are kindly requested not to contact us about the combination of our products with other manufacturers'. 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. CAUTION Work only when the engine and the muffler are cool. (Otherwise, you will burn yourself.) Prepare right tools for the work, and do the work in the proper and right way.(otherwise, improper work could cause breakage of parts or injuries to yourself.) Always use a torque wrench to screw bolts and nuts tight and securely to the specified torque. (Improper torque could cause these parts to get damaged or fall off.) As some products and frames have sharp-pointed or protruding portions, please work with your hands protected. (Otherwise, you will suffer injuries.) The following show the envisioned possibility of injuries to human bodies and property damage as a result of disregarding the following cautions. 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. (Or improper torque may cause parts to come off.) WARNING Always drive the engine in a well-ventilated place, and do not switch the engine on in an airtight place. (Otherwise, you will suffer from carbon monoxide poisoning. ) The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the following cautions. When you notice something abnormal with your motorcycle while riding down a road, stop riding immediately and park your motorcycle in a safe place. (Otherwise, the abnormality could lead to an accident.) Before doing work, place the motorcycle on level ground to stabilize the position of your motorcycle for safety's sake. (Otherwise, your motorcycle could fall down and injure you while you are working.) Check or perform maintenance of parts correctly according to the procedures in the instruction manual or a service manual. (Improper checking or maintenance could lead to an accident.) If you find damaged parts when checking and performing maintenance, do not use these parts any longer, and replace them with new ones. The continued use of these damaged parts as they are could lead to an accident.) 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 the high risk of explosion, work in a well-ventilated place.
Kit Contents 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. There are some parts, however, for which we are not in a position to accept your order in just the quantity to be used. In this case, please take them in the quantity packed.
Features We have equipped the clutch cover with an oil filter using a paper-type element. A thermostat with a spring, made of a shape-memory alloy, is available for use in this kit as an optional extra. (Patent granted.) We have formed the clutch cover and oil filter by die-casting, and used lightweight magnesium alloy, with a specific gravity of 1.7, to make the clutch. We have given the rust-proofing treatment and then put brown liquid painting onto the surface. This kit enables the flow of oil from the clutch cover to oil cooler. This kit comes with an oil pot window with a high level of durability, which is highly evaluated by the Monkey model riders. Equipped with a large-size oil filler cap. Lifter pin direct system, which dose not utilize the cam and adjusting lever, is employed as a clutch operation system. An oil cooler unit, which is installable to the oil filter cover, cannot be installed to this kit due to the size difference. Oil lines can be used only at the specified location. A conventional oil cooler hose cannot be installed to this kit due to the size difference. Please use an oil cooler hose for exclusive use in die-cast covers. Precautions for use If you are using an oil cooler kit to which an oil hose is connected from the cylinder, NEVER install a thermo unit or oil hole plug. There is a possibility that the engine will be damaged due to the oil passage blockage. Please refer to a relative instruction manual for a thermo unit, an oil cooler, and so on. Please do the work, referring to a HONDA s service manual for Ape50, Ape100, XR50 Motard and XR100 Motard. About Oil Lines In the case of Ape50 and XR50 Motard, all the engine oil is provided to the cylinder head and the crankshaft via oil filter. An oil line in the crankcase of Ape100, Ape100 Type D and XR100 Motard differs in shape from the one in Ape50 and XR50 Motard. However, by attaching the provided rubber separator onto the first three types of motorcycles, all the engine oil can be arranged to flow through the oil filter to the cylinder head and crankshaft just like the latter two types of motorcycles. Oil Line Diagram Flow of engine oil To cylinder head To cylinder head To cylinder head Oil filter Oil filter Oil pump Rubber separator (supplied in the Kit) Oil pump Oil pump To crank shaft To crank shaft To crank shaft Crankcase Right crankcase cover Crankcase Right crankcase cover Crankcase Right crankcase cover In the case of Ape50 and XR50 Motard In the case of Ape100,Ape100 TypeD, and XR100 Motard In the case of stock Ape50 / 100, and stock XR50 / 100 Motard
1. Stabilize the vehicle with a maintenance stand. 2. Prepare a tray. Remove the drain bolt and drain engine oil. 3. Unfasten the bolt on the kick starter arm, and remove the starter. Unfasten two bolts on the right-side step bracket, and detach the bracket, rear brake pedal, sleeve and spring. Installation Procedures 4. Disconnect the clutch cable. Detach the engine-mounting upper nuts, and pull out the mounting bolts to demount the clutch cable receiver. Fix the clutch cable receiver included in the kit, and fasten the engine mounting nuts to the specified torque. Torque: 44 Nm (4.5 kgfm) Return spring, sleeve Lock nut Cable receiver Right-side step Rear brake pedal Bolts Adjust nut Bolt 5. Unfasten the bolts on the right-hand crank case cover and remove the right-side cover. 10. Clean up case s mating surfaces, attach the dowel pins and a new gasket, and install the magnesium cover. Be careful not to give damages to the crank shaft and oil seals on the kick 6. Remove two dowel pins and a gasket. Dowel pins starter spindle. 11. Put the washers onto the kit s bolts, which please fix to the cover, and tighten them to the specified torque diagonally in several steps. Torque: 7 Nm (0.7 kgfm) 12. Place the oil filter spring on the protrusion of the right-side crank case cover oil filter. Insert the oil filter into the protrusion of the oil filter cover. Apply engine oil to the O-rings of the oil filter cover, and install them to the right-side crank case cover, being careful that the O-rings are in the right position. And fix and tighten the flange bolt to the specified torque. Torque: 9 Nm (0.9 kgfm) Aluminium washers will not be used here. 13. Connect the clutch cable, and adjust the free play on it. Gasket Free play on the clutch: 10-20 mm at the end of the clutch lever. 7. Remove a clutch lifter pin, and attach a supplied lifter pin, which please 14. Apply grease to the sleeve, which Return spring attach to the bearing in the clutch lifter plate. please fix to the brake pedal, and Two kinds of clutch lifter pins are available to suit the kinds of Rear brake pedal tighten loosely the spring and transmissions. Be sure to use a 5-speed transmission lifter pin for a right-side step bracket with bolts. sleeve 5-speed transmission and a 6-speed transmission lifter pin for a Bolts Apply the rear brake, and after 6-speed transmission. brake-related sections get For 5-speed transmission For 6-speed transmission Two lines warmed up, fasten the bolts to the specified torque. Torque: 39 Nm (4.0 kgfm) right-side step 42.5mm 41.3mm (Installation of rubber separator) In the case of Ape100, Ape100 Type D or XR100 Motard As shown in the photo, attach the rubber separator onto the oil line groove on the right side crankcase with the TAKEGAWA logo being visible and its protrusion being right in the dent of the case. Install the rubber separator without using a hammer or the like. First attach the clutch cover gaskets to the crankcase. And check that the arrowed hole is not blocked up by the rubber separator. And lastly attach the clutch cover. Install the rubber separator with the TAKEGAWA logo being visible. Install the separator with its protrusion being right in the dent of the case. Make sure that this hole is not blocked up. 15. Fix the kick starter arm, and screw up the bolt(s) to the specified torque. Torque: 26 Nm (2.7 kgfm) 16. Tighten the drain bolt to the specified torque, and pour 1,000cc of engine oil. Torque: 25 Nm (2.5 kgfm) Make sure that there is no oil leakage. 8. Install the clutch lever spring and Clutch lever spring the clutch lever to the magnesium cover. Apply engine oil to the clutch lever shaft. Clutch lever 9. Detach the oil filter screen and clean it. Then, fix it firmly to the grooves in the crankcase. Appropriate engine oil level seen through the oil pot, just for your guidance At oil change:0.9 liters At oil filter change:1.0 liters At overhaul: 1.1 liters
Important Notice Oil Cooler Installation In case a thermo unit is to be installed: 1. Install a thermo unit. 2. Unfasten two oil plug bolts, and install an adapter suitable for the kind of hose you will use. Then connect the hose. Please see the instruction manual for the thermo unit. Please see the instruction manuals for the oil cooler kit and the adapter. Rubber hose Allegri s hose In Case of Oil Hose Installation on the Cylinder Head Side CAUTIONNEVER 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 the engine is damaged due to the oil passage blockage. In case an oil cooler is not installed: NEVER install a thermo unit or an oil hole plug. And in case the thermo unit and/or an oil hole plug is installed, DO be sure to remove it or them. CAUTIONThere is a possibility that the engine is damaged because the oil passage will be blocked when the thermo unit or an oil hole plug is installed. 3-5-16 Nishikiorihigashi Tondabayashi Osaka Japan TEL : 81-721-25-1357FAX : 81-721-24-5059 URL : http://www.takegawa.co.jp Co.,Ltd.
About Handling of Magnesium Products Magnesium is about 2/3 as light as aluminium with the specific gravity of 1.7 and 2.7 respectively. A magnesium alloy is lighter than any other metal in practical use, and it excels an aluminum alloy in the shock absorption as well as specific strength. On the other hand, magnesium material is very vulnerable to chemical reactions and corrosion. In view of all that, we have given the rust-proofing treatment and then put liquid painting onto the surface. CAUTIONS (important) The paintwork may be cracked or peel at the time of bolt tightening or parts fitting. Moreover, the paintwork may be damaged by a hit or a flying stone. Please handle the products with care. The difference in thickness because of the shape difference may cause cavities to occur on the work surfaces, which is characteristic of die-cast products. But the cavities do not affect the product performances. Usually, the durability of magnesium alloy is slightly inferior to that of aluminum alloy due to corrosion. Therefore, periodic checks of various parts for cracks or corrosion are essential. Please never process any magnesium product. Because of the chemical-reaction-prone material, cuttings during cutting operations will catch fire when they get hot by the processing heat, or when placed near a flame. The larger the surface areas are (like small or thin items) in comparison with the volume, the more prone the items get to catch fire. Moreover, pouring water on the burning magnesium triggers chemical reactions, which is quite dangerous. How to Maintain the Products Clean the dirt adhering to the surface with a soft cloth. As for tough stains, wipe them away with a well-wrung cloth after soaking it in the liquid nuetral detergent and clean up the moisture with a dry cloth.. Observe the following for the safe and longer use of the products Please clean up the moisture when the parts got wet from running in the rain or washing. When paintwork is cracked or peeled, repair the portions with repairing paint without delay. If the metal gets scraped or chipped, have the parts mended, or exchange them with new ones. In case you coat magnesium products with paint, never peel the existing coating. Once you get rid of the rust-proof treatment, its resistance to corrosion will significantly decline. Every time you disassemble the magnesium products, be sure to always change the proper washers, used to mount bolts, with new ones. Continuous use will damage the coating. Besides, always use flange bolts, included in the kit, for mounting parts. Other types of bolts are likely to damage the paintwork because of contact pressure. Please purchase aluminum washers for repair (Item No.: 020-01-0001 containing 20 sheets). Co.,Ltd. 3-5-16 Nishikiorihigashi Tondabayashi Osaka Japan TEL : 81-721-25-1357FAX : 81-721-24-5059URL : http://www.takegawa.co.jp