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3.Attach to spring plate the removed ball
bearing holder, and ball bearing, and
attach a provided clutch lift rod to the
ball bearing.
Attach a provided shim ring to the
change-shaft.
Lift rod
Shim ring
4.Degrease the clutch-cover mounting
surface of the crankcase.
Put in two dowel pins into the crankcase,
and attach a new clutch cover gasket.
Attach a right crankcase cover, and
fasten it with a provided socket cap
screw in a few steps in the order as
specified below.
Caution: Apply the specified torque.
Socket cap screw
Torque：8.8N・m（0.9kgf・m）
※ Check that a clutch release rack is
attached inside the cover.
※ Attach the right crankcase cover with
care not to damage an O-ring of a kick
shaft.
※ And jointly fasten a clutch cable
receiver and the O-ring in place.
※ Fasten an ground cord and the cable
receiver.
(This applies only to KSR110.)
Fasten cable receiver.
②
③
⑦
⑨
⑥
①
5.Put a 10 mm washer into the release pinion
with the washer' s round edge facing downwards.
Hang one end of a clutch arm spring on the
release arm, and the other end on the cover.
And position the release arm in place as
per the figure below.
※ Turn the release pinion clockwise until
it comes to a halt, and attach the
release arm.
Release arm
Arm spring
Attach a socket cap screw to the release
arm. And pressing down the release arm
lightly, tighten the socket cap screw.
Caution: Apply the specified torque.
Socket cap screw
Torque：8.8N・m（0.9kgf・m）
2020.11.4
6.Attach a bracket to the provided clutch
lever, and spring pin with a plastic hammer.
※ If using in KSR110, please remove genuine
mirror bracket.
※ If you are installing a rearview mirror in
KSR110, it is used in assembling the
included mirror bracket to the clutch
master cylinder ASSY.
※ For vehicles of KSR PRO(KL110EEF), the
included clutch lever ASSY is not used, it
is recommended the clutch lever use of
genuine.
7.Attach a clutch lever to the steering
handle, and tighten the bolt.
Caution: Apply the specified torque.
Bolt
Torque：8.8N・m（0.9kgf・m）
8.Attach a clutch cable adjuster to the
release arm.
Detach a nut on the clutch cable adjuster
completely from the screw, and pass a
cable through the clutch cable receiver.
Reinstall the removed nut, and fasten the cable
receiver in be tween nuts loosely initially.
Route the clutch cable to the clutch lever
without stretching it by force, and attach
the cable end to the lever Adjust the free
play at the clutch lever with an adjuster
Fasten ground cord.
on the clutch cable, and fasten thenut.
(KSR110)
Caution: Apply the specified torque.
⑩
Nut
⑤
Torque：11.8N・m（1.2kgf・m）
Free play at the lever tip: 10 ～ 20 mm
※ Fine-tune the free play with the adjuster
on the clutch lever
9.Install the removed right step holder,
brake pedal and kick pedal.
⑧
Caution: Apply the specified torque.
Right step-holder bolt
Torque：26N・m（2.7kgf・m）
Brake-pedal bolt
Torque：8.8N・m（0.9kgf・m）
④
Kick-pedal bolt
Torque：11.8N・m（1.2kgf・m）
Kick-pedal bolt
Brake-pedal bolt
10.Fasten a drain plug, and add engine oil.
Caution: Apply the specified torque.
Drain plug
Torque：29N・m（3.0kgf・m）
※ In case a gasket on the drain plug always,
replace it with a new one.
Engine oil level: 0.9 liter (at the time of oil
change)
※ Use the following figure just as a guideline on
how to read the oil level through oil pot window.
02-01-0404,0405,0408,0409
Spring pin
Mirror bracket
Step-holder bolt
0.9L
0.8L
0.7L
4/4
Important Notice
Installation of oil cooler:
(In the case of installing the thermo unit)
Please be sure to use a thermo unit of
Item No.02-01-5052 coming with a gold cap.
Please note that a thermo unit of Item No.
02-01-5053 coming with a blue cap is not
usable(because of different screw diameter).
1.Install the thermo unit according to the
Instruction Manual.
2.Detach two oil plug bolts, attach hardware
like a banjo to match the kind of hose to
be used, and connect the hose.
※ Please see an Operation Manual for the
thermo unit.
※ Please see an Operation Manual for the
oil cooler kit.
Thermostat unit or
oil drain plug hole
（When not installing the thermostat unit）
Remove the thermostat hole cap, attach
the oil hole plug (included in our oil
cooler kit), and tighten to the specified
torque.
Caution: Apply the specified torque.
Thermostat hole cap
Torque：13N・m（1.3kgf・m）
Caution:When connecting an oil hose to the
clutch cover, you must install a
thermostat or an oil hole plug.
Without thermostat or an oil hole
plug installed,
oil will not circulate and the
engine may be damaged.
(In the case of connecting the oil hose
to other hardware than the clutch cover)
NEVER install a thermostat or an oil hole
plug if you connect an oil hose to the
oil filter or cylinder-head oil pipe.
Caution:NEVER 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.
Caution:There 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.
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