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● 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.
○ 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
Mounting procedure ※ With regard to the mounting method and the specified torque of detail, refer to the genuine service manual.
■
● 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)
a
b
c
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.
2020.11.4
Safety Precautions for Use
7.Remove a change pedal to pull out a
change-shaft lever.
Remove a change-shaft return spring from
the change-shaft lever.
8.Remove a bolt for engine ground wire on
the crankcase.
(This is applicable only to KSR110)
d
e
● 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 holder spring
Clutch holder
02-01-0404,0405,0408,0409
Bolt for earth wire
Change-shaft return spring
Change shaft
Clutch gear
Ring
Primary-clutch housing
3/4
● Assembly and installation:
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.
Caution: Apply the specified torque.
Nut 14mm
Torque：72N・m（7.3kgf・m）
Tighten a 14mm nut, holding the primary
drive gear.
Caution: Apply the specified torque.
Nut 14mm
Torque：72N・m（7.3kgf・m）
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