Special Clutch Cover Kit (Wire type) Instruction manual

Product number 02-01-0150 GROM :JC61-1000001 ～ 1299999

:JC61-1300001 ～
Adaptation model :JC75-1000001 ～
MSX125
MSX125SF

Thank you very much for purchasing our products.

Thank you so you will comply with the following matters at the time of use.Before installation, please check your always kit contents.
If there is a point of notice event, Please contact us the dealer of purchase.
◎ If the description, such as photos or Illustration different with this part.
☆ Please read carefully before use ☆
◎ The use ignoring the instructions that are written in the manual, if the accident or damage has occurred, we can not assume any
responsibility for compensation.

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◎ This product installation and use, when a problem occurs to after market goods, guarantee other than this product, also can not
assume any in any such matters.
◎ If it was the case or mounting that has been processed like a product, it will not be covered under warranty.
◎ It is not possible to inquire of the combination of other manufacturers.
◎ This product is the above-mentioned vehicle exclusive goods.Is not possible attached to the other vehicle. Please note.
◎ Please refer to the genuine service manual for the above-mentioned compatible models for the assembly work.
◎ Special tools are required to install this product. Please prepare separately.
Lock nut wrench：07916-6390001(Genuine Honda tool) or Lock nut wrench：00-01-0152(Takekawa tool)
Gear holder：07724-0010100(Genuine Honda tool) or Universal holder：00-01-1002(Takekawa tool)
～ feature ～
・Rack & pinion wire clutch cover that enables light and smooth operation.
・R.Crankcase cover is made of die-cast aluminum with black paint, and clutch cover is made of forged aluminum with shot blast.
・By adopting a paper cartridge oil element, the centrifugal oil filter can be removed and reducing the load on the crankshaft and
improving engine response.
・Thermostat unit (02-01-5052: optional) can be installed. Thermostat prevents overcooling whith oil cooler.
・The oil level window makes it easy to check the oil level.

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・Filtered oil flows through the oil element by two passage (crankshaft / transmission) with this kit.
(In the stock clutch cover, only one crankshaft passage passes through the centrifugal filter from oil pump).
※ By connecting our bore-up cylinder (oil outlet equipped model) and oil line hose kit (00-07-0095: optional), the oil through the oil
element can flow to the cylinder head.
・Clutch cover for stock clutch or Takegawa slipper clutch.
In addition, it is possible to upgrade to a clutch cover that supports heavey dutey clutches (wet or dry) by installing optional items.

Caution When the handling of ignoring this display, property damage and human shows the assumption of what injury.

■ On the street, keep the legal speed and obey the traffic law.
（If you drive faster than the legal speed, you will be punished for violating the Road Traffic Act and overspeeding.）
■ When performing the work, etc., be sure during the cold (when the engine and the muffler is cold). (It may cause burns.)
■ When performing the work, it should be made to prepare the tools for the job. (Breakage of parts, it may cause injury.)
■ Do the work must always specified torque using a torque wrench. (Damage of bolts and nuts, and cause of dropout.)
■ The product and the frame, might have edges or protrusions. Please go to protect your hands when you work. (It may cause injury.)
■ Be sure to each part inspection before operation, check the loosening of the threaded portion, be sure to securely tighten the
specified torque if there is loose. (It may cause detachment of the parts.)

Warning When the handling of ignoring this display people died, shows the contents of the serious injury possibility is
assumed.
■ The technology and those who no knowledge, please do not to work.(The cause of parts damage etc., could result in falls and accidents.)
■ If you start the engine, be sure in a well-ventilated place. In the sealed such place, please do not start the engine.
(There is a risk of carbon monoxide poisoning.)
■ During operation, when an abnormality occurs, immediately stop the vehicle in a safe place, please stop running. (It may lead to an accident.)
■ When performing the work, do the work safely stabilize the vehicle in a horizontal location.
(There is a risk of injury vehicle collapsed while working.)
■ Inspection, maintenance, the instruction manual or, inspection methods such as service manuals, to protect the way, should be done
correctly.(unsuitable inspection and maintenance, there is a risk that result to an accident.)
■ When carrying out the inspection and maintenance, etc., if found damaged parts, replace the damaged parts to avoid possible to reuse
the parts.(There is a risk that lead to accidents Continued use.)
■ The engine and exhaust system are hot while the engine is running or for a while even the engine is stopped.Never place dangerous or
flammable materials such as gasoline near working area. (May caused fire.)

◎ Please note. Performance up, the design change, the product and the price in the cost up, etc. are subject to change without notice.
◎ Please be informed that we shall be held harmless against any claim against us whatsoever arising out of use of the products in
racing and the like.
◎ Keep this manual stored until this product is discarded.

CONTACT Address : 3-5-16 Nishikiorihigashi Tondabayashi Osaka JAPAN

TEL: +81-721-25-1357 FAX:+81-721-24-5059 e-mail:[email protected] URL http://www.takegawa.co.jp
Please contact with your name and country name provided. (Only English please)
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 Product content

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32 40

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Number Product content Quantity Item Number Number Product content Quantity Item Number
1 R.crankcase cover ASSY. 1 00-02-6208 22 O-ring, 120mm 1 00-02-0188
2 Oil pot window set 1 00-02-0031 23 Clutch cable receiver COMP. 1 00-00-1676
3 Thermostat hole cap 1 00-07-0063 (with O-ring) 24 Oil filter spring 1 00-07-0065
4 O-ring, 15mm 1 00-00-0185 (5 pcs) 25 Oil filter element 1 00-02-0027
5 Hole cap 1 09-06-0131 (with O-ring) 26 O-ring, 40mm 1 00-02-0040
6 O-ring, 30mm 1 00-01-0034 (4 pcs) 00-02-0470
27 Oil filter cover 1
00-07-0072 (with O-ring/Bolt)
7 Oil plug bolt 3
(with Sealing washer) 28 Boll bearing, 6001Z 1 00-01-1011
8 Sealing washer, 10mm 3 00-07-0106 (10 pcs) 29 C type ring, 28mm 1 00-00-0643 (3 pcs)
9 Flange bolt, 6x12 1 00-00-0322 (6 pcs) 30 O-ring, 12mm 1 00-00-0136
10 Sealing washer, 6mm 2 00-00-2780 31 Oil through nut 1 00-00-2310
11 Oil filler cap 1 00-02-0468 (with O-ring) 32 Conical spring washer, 14mm 1 00-02-0036
12 O-ring, 13mm 1 00-00-0644 (5 pcs) 33 Spacer 1 00-00-1414
13 Clutch cover COMP. 1 00-00-1089 34 Clutch lifter rod, 10mm 1 00-00-1684
14 Oil seal, 10x17x5 1 00-02-0006 35 Clutch lifter rod, 12mm 1 00-00-1685
15 Clutch release pinion 1 00-02-0033 36 Orifice 1 00-00-1072
16 Extra low head cap screw, 6x8 1 00-00-0642 (6 pcs) 37 R.crankcase cover gasket 1 00-02-0356
17 Flat head screw, 4x10 1 00-00-0190 (6 pcs) 38 Clutch cable COMP. 850mm 1 00-02-0133
18 Release arm 1 00-02-0469 (with Bolt) 39 Dowel pin, 8x12 2 00-00-0153 (2 pcs)
19 Clutch arm spring 1 00-02-0112 40 Flange bolt, 6x16 2 00-00-0879 (5 pcs)
20 Plain washer, 10mm 1 00-00-0151 (10 pcs) 41 Socket cap screw, 6x18 1 00-00-0720 (5 pcs)
21 Release rack 1 00-02-0039 42 Socket cap screw, 6x15 4 00-00-0718 (5 pcs)

※ Please order in the repair parts are always repair part number.
If it is not the part number order, you may not be able to order.Please be forewarned.
It should be noted, In the case of parts that can not be separately shipment, please order a set part number.

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 ■ Mounting procedure ※ Please refer to the Genuine Service Manual for detailed mounting methods and specified torques that are not
specifically described.

・Park the motorcycle in a horizontal place ・Remove washers and centrifugal filter rotor. ・Attach R.Crankcase cover, clamp and cable
with a maintenance stand, etc. receiver COMP. with genuine bolts, divide
・Drain engine oil. bolts several times diagonally and
・Remove the R.step holder. tighten to specified torque.
R.step holder
Note:Be sure that you protect specified torque.
Bolt
Torque：10N・m（1.0kgf・m）

Pivot nut ・Attach the O-ring(12mm) to the oil through

nut and apply a engine oil to the O-ring.

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O-ring
Mounting bolt

・Disconnect clutch cable.

・Loosen the bolts of the R.crankcase cover
several times diagonally and remove the
R.crankcase cover and clamp.

・Attach the spacer, conical spring washer,

and oil through nut to the crankshaft in
this order, hold the spacer with a
spanner, and tighten the oil through nut
to the specified torque.
Note:Be sure that you protect specified torque.
Nut
・Remove R.crankcase cover gasket, dowel Torque：64N・m（6.6kgf・m）
pin and orifice.

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Dowel pin ・Attach the lifter rod in the kit to the
ball bearing on the clutch lifter plate.
※ Use 10mm lifter rod for stock clutch,
12mm lifter rod for Takegawa slipper
Spacer Conical spring washer Oil through nut
(Note the direction) clutch.

Orifice

・Remove the bolt, centrifugal oil filter

cover and gasket.
Centrifugal
oil filter cover

・Attach the O-ring(120mm) to the clutch

Bolt Gasket Installing the clutch cover cover and apply a engine oil to the
・Hold the primary drive gear and driven O-ring.
・Clean the gasket surface of the R.crankcase,
gear or the centrifugal oil filter rotor, attach the dowel pin, and install a new
and remove the centrifugal filter rotor R.crankcase cover gasket.
lock nut using a special tool. ・Attach the orifice in the kit to the back of
Special tool the R.crankcase.
：Genuine Honda tool
Lock nut wrench 07916-6390001
Gear holder 07724-0010100
：Takekawa tool ・Apply grease to the release rack and
Lock nut wrench 00-01-0152 attach it to the clutch cover.
Universal holder 00-01-1002

Lock nut wrench Gear holder

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 ■ Mounting procedure ※ Please refer to the Genuine Service Manual for detailed mounting methods and specified torques that are not
specifically described.

・Attach the clutch cover to the R.crankcase ・Turn the clutch release pinion clockwise ・For GROM(JC61-1300001 ～ /JC75-1000001 ～ ),
cover, install it with the socket cap until it stops, and insert a plain washer MSX125SF
Since the rubber cap of the clutch cable
screw(6x15) and tighten it to the into the release pinion.
and the clamp welded to the frame are
specified torque. close to each other, if they interfere,
Note:Be sure that you protect specified torque. bend the clamp and provide clearance.
Socket cap screw,6x15 Clamp
Torque：10N・m（1.0kgf・m）

・Attach the cable end to the release arm,

set the release arm spring, insert the
inner cable into the release pinion while
the cable pulled, and hook the arm spring

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to the cover.
・Attach the socket cap screw(6x18) to the
release arm and tighten the socket cap
screw to the specified torque with the arm
pushed in.
Note:Be sure that you protect specified torque.
Socket cap screw
Torque：10N・m（1.0kgf・m）
Installing the oil filter cover
・Place the oil filter spring in the
・Attach the removed R. step holder.
R.crankcase cover (fit it into the guide
Note:Be sure that you protect specified torque.
of the case), put the oil filter, attach Swing arm pivot nut
the O-ring(40mm) to the oil filter cover, Torque：54N・m（5.5kgf・m）
apply engine oil, and attach the flange Step holder mounting bolt
bolt(6x16), Tighten with specified torque.
Torque：31N・m（3.1kgf・m）

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Note:Be sure that you protect specified torque. After assembly
Flange bolt
・After confirming that the drain bolt
Torque：10N・m（1.0kgf・m）
{T=21.5N・m(2.2kgf・m)}is tightened, pour
※ Make sure the oil filter attached the engine oil, attach the O-ring to the hole
guide on the oil filter cover. cap, apply a small amount of engine oil to
the O-ring, Tighten to the specified torque.
※ Caution:If the oil filter spring does not ・Adjust the clutch free play at the adjustment
Note:Be sure that you protect specified torque.
fit inside of the guide(of the oil filter), part of the clutch cable, tighten the nut
Torque：12N・m（1.2kgf・m）
there will be a gap between the oil filter to the specified torque, and cover each
cover and the R.crankcase cover. This may with a rubber cap. ※ Engine oil viscosity and volume affect
clutch disengagement.
cause the oil leaks. Note:Be sure that you protect specified torque.
Be careful to use high viscosity or volume
Nut
O-ring of the oil.
Torque：10N・m（1.0kgf・m）
Also, avoid excessive mixing of molybdenum,
Rubber cap additives etc., as this may cause the
clutch to slip.
※ Check the oil level of the oil window
Nut frequently, and add it if it is lower
Nut than the reference level.
Rubber cap

upper limit
Installing the clutch cable
・Attach the clutch cable to the clutch lower limit
lever and route it to the clutch cable
receiver for the cable is not overloaded.
・Attach the adjuster of the clutch cable ※ Oil volume when disassembling the crankcase
to the cable receiver. ：about 1100cc
Clutch free play
Oil volume for oil change：about 900cc
10 to 20 mm at the clutch lever end
・Shift the transmission to first gear with
10 ～ 20mm the engine stopped and squeeze the clutch
lever.
When moving the vehicle, make sure that
the rear wheel does not rotate when the
rear wheel rotates and the clutch lever
is released.
・Start the engine with the transmission in
neutral and check all parts for oil leaks.
If there is no problems, test ride at
low-speed in a safe place to check the
operation of the clutch.
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 ■ Mounting procedure ※ Please refer to the Genuine Service Manual for detailed mounting methods and specified torques that are not
specifically described.

Caution ● When installing an oil hose to the

oil outlet of the cylinder
Precautions when installing an Note:Never attach the thermostat unit or oil
oil cooler hole plug when the oil hose is not
connected to the clutch cover.
● When installing an optional
Oil passage will closed and engine may
thermostat unit be damaged.

・Installing the thermostat unit.

・Remove the two oil plug bolts, attach an
adapter that matches the type of hose to
be used, and connect the hose. When not installing an oil cooler
※ Check the thermostat unit instruction
・Never install a thermostat unit or oil hole

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manual.
※ Check the oil cooler kit instruction plug.
manual and adapter instruction manual. Remove a thermostat unit or oil hole plug.
Note:When the thermostat unit or oil hole plug
is installed, the oil passage is closed
and the engine may be damaged.

● When not installing the thermostat

unit

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・Remove the thermostat hole cap and insert
the oil hole plug (00-02-0391) into the
oil hole.
・Apply engine oil to the O-ring of the
thermostat hole and tighten the hole cap
to the specified torque.
Note:Be sure that you protect specified torque.
Hole cap
Torque：13N・m（1.3kgf・m）

Oil hole plug

Thermostat
hole cap

・Do not use oil hole plugs (00-02-0111).

Note:If use the oil hole plug (00-02-0111),

the oil passage will be closed and the
engine may be damaged.

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