Instruction Manual for Racing-Type Back Step Kit(Rear damper hub type & racing back step)
Item No.
Fits：０６−１３―０００２：Monkey・Gorilla

Frame Nos ：Z50J-1300017〜
Thank you for purchasing one of our TAKEGAWA’s products.
This back step is so designed that a kick pedal and stop lamp switch can be used only for street use. And the riding position is also designed to be suitable
for the racing as well.
Before starting the installation, please read this Instruction Manual well for your thorough understanding and proper installation.
◎ Please note that, in some cases, the illustrations and photos may vary from the actual hardware.

Please read the following instructions before installation.
The following show the envisioned possibility of injuries to human bodies or property damage as a result of disregarding the following

Caution cautions.

○ Be sure to do the work when the engine and muffler are cold. (Otherwise, you will get burned.)○ Tighten to a specified torque using a torque wrench. (Otherwise, improper tightening may cause the bolts or nuts to get damaged or come off.)○ As some products and frames have sharp-pointed or protruding portions, please work with your hands protected. (Otherwise, you will suffer injuries.)○ Before riding, always check every hardware 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.)○ Be careful the brake fluid does not contact your skin. After work, wash your hands thoroughly with water. Otherwise, you will have a rough skin.
○ Please handle the brake fluid with great care, because the fluid, if spilled on painted surfaces, resin parts, or rubber products, will deteriorate ordamage these parts. If the fluid is spilled on them, wash them immediately with water. Otherwise, the fluid spill will cause the deterioration or damageof these parts.
The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding theWarning following warnings.

○ Installation of this Kit requires processing. So, when working, please take precautions to protect your eyes, face and hands for safety's sake.
(If metal fragments or others get in your eyes, this may cause your vision loss.)○ When you notice something unusual with your motorcycle while riding down a road, immediately stop riding. (Otherwise, accidents may take place.)○Keep plastic bags for packing the products out of children's reach, or discard them. (If children get them on, there will be a danger of their suffocating.)○ Before starting the work, secure your motorcycle firmly on level ground for safety's sake.
(Otherwise, your motorcycle could overturn and injure you while you are working.)○Do not get oil or grease on the brake disk rotor or brake pad. If oil &/or grease adhere to these parts, change the brake pad and degrease the brake disk
rotor. Otherwise, oil or grease adherence may lead to accidents.
○We recommend you to get the brake installed by a skilled mechanic at facilities with special instruments and tools. Otherwise, the wrong installation may
cause accidents.
○Carry out inspection and maintenance of your motorcycle correctly according to the instructions and guidelines in the instruction and service manuals.
(Improper inspection or maintenance could lead to accidents.)○ If you find damaged parts when inspecting or performing maintenance of your motorcycle, do not use these parts any longer, and replace them withnew ones. (The continued use of these damaged parts as they are could lead to accidents.)★We listed here the cautions and warnings for users to use these parts properly and also to prevent dangers and damages to users themselves and otherpeople as well. All these are the envisioned dangers and damages which are feared to take place from wrong handling. So, please do follow these
instructions for safety's sake.
◎ Please be informed that, mainly because of improvement in performance, design changes, and cost increase, the part specifications and prices are
subject to change without prior notice.
◎In placing a repair parts order with us, please quote the repair parts Item Nos. as well as the Item Nos. Should you have any questions about the repair
parts, please contact your local motorcycle dealer.
◎ This manual should be retained for future reference.
◎ We do not take any responsibility for any accident or damage whatsoever arising from the use of the products not in conformity with the instructionsin this Manual.
◎ We shall be held free from any responsibility or compensation whatsoever for any glitch in the parts other than ours if the glitch takes place after the
installation and use of this Kit.
◎ You are kindly requested not to contact us about the combination of our products with other manufacturers'.
◎ If you use a side stand, please use the side stand of Item No. 09-12-035.
◎ This Kit can work only with a TAKEGAWA's kick starter arm of Item No. 09-10-004.
‑1‑

Sep./28/ 09

〜 Kit Contents 〜
２５
３４
３４
１１
１４

４
２２
３５ １２

Ａ

１３
２９
６
Ｂ

２８

３９

３１

Ｄ
Ｃ

３４
３６

Ａ

Ｃ

２４

３

Ａ

４１

２７

２０

３８

４２
４４
４３

Ｂ

４０

２４

４１
１５

７
２７

２

３３

１７

３３
２６

１８
３２
９
１６

１
２３４４
２８

４７ ４６ ４５

２４
２４

１９
１０
３５

８

７

３５

２６
３６

２８

Ｄ
Ｃ
Ｂ

３６

Ａ

３１
２１３７
５

３

３０

No.
1
2
3
4
5
5-A
5-B
5-C
5-D
6
6-A
6-B
6-C
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23

Part Name
Qty
Brake holder
1
Change holder
1Foot rest2
Foot rest end
2
Brake pedal COMP.
1
Pedal
(1)
Pedal rubber(1)
Pedal collar(1)Flat head screw, 6 x 30
(1)
Change pedal COMP.
1
Pedal
(1)
Pedal rubber(1)
Flat head screw, 6 x 25
(1)
Pedal collar
2
Spring hook1
Stop switch stay1
Return spring
1
Change arm
1
Rod end 6 (6mm clockwise screw) 1
Rod end 6L (6mm left-hand screw) 1
Change rod
1
Holder stay1
Mounting nut, S, marked
1
Mounting nut, L
1
Mounting shaft
1
Master cylinder bracket
1
Heel guard, L
1
Rod end (6mm female screw)
1
Socket cap screw, 8 x 60
2
Socket cap screw, 6 x 15
1

Repair Part Item No.
50630-GEF-T00
50710-GEF-T00
50640-181-T10
50641-181-T00
46520-GEF-T00
24701-181-T00
06-08-0005
46503-181-T00
00-00-0119
24700-GEF-T00
24701-181-T00
06-08-0005
00-00-0120
46531-181-T00
46515-181-T00
35351-GEF-T00
46514-181-T00
24702-181T-00
00-00-0122
00-00-0123
24731-181-T00
95707-181-T01
95702-181-T01
95703-181-T00
95701-165-T00
43511-181-T00
50722-181-T00
00-00-0124
00-00-0125
00-00-0042

in packs of
1
1
1
1
1
1
1
1
4
1
1
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
10

No.
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
38-A
39
39-A
39-B
39-C
39-D
40
41
42
43
44
45
46
47

Part Name
Qty
Socket cap screw, 8 x 20
4
Button head screw, 6 x 25
1
Flange lock nut, 8 mm
2
Button head screw, 6 x 12
2
Hex nut, 6 mm （Clockwise screw） 3
Hex nut, 6 mm L（Left-hand screw） 1
Button head screw, 6 x 30
1
Lock nut, 6 mm
2
Stop switch spring
1
Flange socket cap screw, 6 x 16
2
Plain washer, 6 mm
3
Button head screw, 6 x 15
3
Button head screw, 6 x 20
3
Collar1
Rear master cylinder sub ASSY.
1Master cylinder piston set(1)
Reservoir tank COMP.
1
Cup COMP.
(1)
Cap
(1)
Diaphragm(1)
Diaphragm plate(1)
Oil hose1
Hose clamp
2
Reservoir tank stay1
Button head screw, 8 x 15
1
Plain washer, 8 mm
2
Hex wrench, 4 mm
1
Hex wrench, 5 mm
1
Plain washer, 6 mm
1

Repair Part Item No.
00-00-0117
00-00-0126
00-00-0080
00-00-0127
00-00-0128
00-00-0129
00-00-0130
00-00-0121
00-06-0005
00-00-0131
00-00-0086
00-00-0132
00-00-0084
43532-181-T00
06-08-1731
06-08-0012
06-08-0006
06-08-0013
06-08-0007
06-08-0008
06-08-0009
00-07-0011
00-00-0087
43610-181-T00
00-00-0085
00-00-0076

２２

４

in packs of
4
5
5
5
10
10
5
10
1
6
10
4
5
1
1
1
1
1
1
1
1
1SET
4
1
4
10

※ 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 inthe quantity packed.
‑2‑

Sep./28/ 09

○ Please check the kit contents, first.
CAUTION : Be sure to prepare tools to suit yourwork.
CAUTION : Check that the engine and muffler
are cool.
WARNING: Make sure that the bike is secure onlevel ground.
○Install and tighten the heel guard L onto a change
holder with a 6x12 button head screw.

○Unfasten three bolts on the left crankcase cover
to remove the cover.

CAUTION : Be sure to always follow the speci
fied torque.
Torque: 10 N・m (1.0 kgf・m)○ Process, with a hand grinder, the detached left
crankcase cover so the portion interfering withthe mounting nut does not interfere any longer.
After processing, file the edge portions smooth tobe without a burr.
WARNING: Be sure to wear eye, face and handprotectors during your work.
○ To remove stock brake pedals, unfasten a split
pin holding the brake rod of stock brake pedals,
and another split pin holding a brake return spring,stop switch spring and brake pedal.
○ Unfasten four bolts which are holding a stock
step bar to remove the step bar.
○ Remove the rear stop lamp switch from theframe.
○ Remove the stock kick pedals.

○ Install the left crankcase cover.

○Fit the pedal collar into the brake pedal COMP.,
and put the foot rest into the locating pin on thepedal collar. Similarly, fit the pedal collar into thechange pedal COMP., and put the foot rest into
the locating pin on the pedal collar.
◎ Put the footrest straight into the pedal collar sothese parts are to be fit closely tight.

Holder stay

Flange socket cap screws○Fix loosely for now the holder stay into the tap on
the frame, which held the rear fender, with a 6x16
flange socket cap screw.

15 mm○ Replace the 8x98 mounting bolt in the lower
part of the engine mount with a supplied
mounting shaft.

CAUTION : Be sure to always follow thespecified torque.
Torque: 10 N・m (1.0 kgf・m)○With a 6x15 socket cap screw and a 6mm hex
nut (clockwise screw), tighten and lock the 6mm
hex nut (clockwise screw) at a tap on the rearside of the brake holder with a head of the 6x15
socket cap screw being 15 mm apart from thebrake holder surface as shown in the figure
above.
CAUTION : Be sure to follow the specified torque
Torque: 10 N・m (1.0 kgf・m)Mounting shaft○Attach the spring hook to the tap on the reverse
side of the brake pedal COMP., and tighten it.

Torque rod bracket(On the brake side)Mark○Install the brake pedal COMP. to the brake holder
with an 8x60 socket cap screw and a flange
lock nut, and tighten it.
And in the same way, install the change pedal
COMP. to the brake holder with an 8x60 socket
cap screw and a flange lock nut, and tighten it.
CAUTION : Be sure to always follow the speci
fied torque.
Torque: 27 N・m (2.7 kgf・m)○Install the mounting nut onto the just-installed
mounting shaft and tighten the nut.
CAUTION : Be sure to follow the specified torque.
Torque: 25 N・m (2.5 kgf・m)◎ On the right (or brake) side
: Install a torque rod bracket and a marked
mounting nut in this order onto the mounting
shaft.
◎ On the left (or change) side
: Install the mounting nut to the mounting shaft.

○Install the master cylinder bracket to the brakeholder and tighten it with a 6x20 button head screw.
CAUTION : Be sure to follow the specified torque.
Torque: 10 N・m (1.0 kgf・m)‑3‑○Beat in the supplied foot rest end into the footrest with a plastic hammer or the like.
Sep./28/ 09

○ Decide on where to locate the brake holder andchange holder, and tighten them to the specified
torque.
CAUTION : Be sure to follow the specified torque.
Torque: 23 N・m (2.3 kgf・m)○ Install a rear stop lamp switch onto the stop
switch stay.

○Install and tighten the other tip of the rod end as
well onto the change pedal COMP., with a 6x15
button head screw.
CAUTION : Be sure to follow the specified torque.
Torque: 10 N・m (1.0 kgf・m)○ Tighten the 6x16 flange socket cap screw, which
is holding the holder stay, to the specified torque.
CAUTION : Be sure to follow the specified torque.
Torque: 14 N・m (1.4 kgf・m)○Adjust the positioning of the change pedal byturning the change rod, and tighten the 6mm hex
nuts to lock the change rod.
CAUTION : Be sure to follow the specified torque.
Torque: 8N・m (0.8 kgf・m)○ In the following way, install, for now, the brakeholder. Put the 8mm plain washer between thebrake holder and mounting nut. Then, put thestop switch between the brake holder andholder stay, and install the brake holder with asocket cap screw, loosely for now.

○ Install loosely for now the 6mm hex nut(clockwise screw) and rod end (6mm female○ Install the supplied change arm to face upwards
and tighten it.

screw) onto the rod on the master cylinder
COMP.

CAUTION : Be sure to follow the specified torque.
Torque: 12 N・m (1.2 kgf・m)ＡＡ○In the same way, loosely install the change
pedal holder with an 8x20 socket cap screw.

Rear-stop
lamp switch

itch
sw e
top brak esebdTh y an ould thista er sh lel w
ld raloha er.
pin h othcea○Screw in a 6mm hex nut L (left-hand screw) to
the supplied rod end 6L (6mm left-hand screw),and install them on the marked tip of the changerod. And in the same way, install a rod end 6 (6mmclockwise screw) and a 6mm hex nut (clockwise
screw) on the other tip of the change rod○ As shown in the above fig., set the positioning ofboth of the rod end A’s so they stick out the samelength.

○Install and tighten the master cylinder COMP.
onto the master cylinder bracket on the brakeholder with the 6x15 button head screw.
CAUTION : Be sure to follow the specified torque.
Torque: 10 N・m (1.0 kgf・m)○ As shown in the fig. above, decide where tolocate the stop switch stay which was installed
between brake holder and holder stay.

○ As shown in the figure below, place plain
washers on both sides of the loosely installed rod
end, which should be installed onto the change
arm with a 6x25 button head screw and a locknut.
CAUTION : Be sure to follow the specified torque.
Torque: 10 N・m (1.0 kgf・m)‑4‑

Sep./28/ 09

○Install a reservoir tank stay to the oil cup COMP.

○ Place a collar between the rod end (6mmfemale screw) attached to the master cylinderand brake pedal, and install and tighten themaster cylinder with a 6x30 button head screw
and a lock nut.
CAUTION : Be sure to follow the specified torque.
Torque: 10N・m (1.0 kgf・m)○ Fix a return spring to the following two: the 6x15
socket cap screw attached to the rear side of abrake holder, and the groove on the inside of aspring hook attached to the rear side of the brake
pedal.
CAUTION : Do the work with great care, using aspring hook and other tools.
Processing

To a rear stop lamp switch

with an 8mm plain washer and 8x15 button headscrew.
CAUTION : Be sure to follow the specified torque.
Torque: 10N・m (1.0 kgf・m)○ Remove the seat.
○ Remove the carrier.
○ If our Rear Cowl Kit is installed onto yourmotorcycle, please remove the rear cowl.

Stop switch spring
To a spring hook

○ As shown in the figure, process the stop switch
spring so it fits into the grooves on the outside of
the spring hook installed onto the brake pedal.
○ Attach the stop switch spring to the rear stop
switch mounted on the stop switch stay.
○Install the kick starter arm.
CAUTION : Be sure to follow the specified torque.
Torque: 12N・m (1.2 kgf・m)○On the motorcycle equipped with our Rear Cowl
Kit, install the reservoir tank stay to the tap on
the seat stay with a 6mm plain washer and 6x20
button head screw.
CAUTION : Be sure to follow the specified torque.
Torque: 22 N・m (2.2 kgf・m)○ If a carrier was installed to your motorcycle,
install the reservoir tank stay to the tap to which
the carrier was attached.
○ Route the brake hose so the brake hose COMP.
will not stretch tight when the hose iscompressed to a maximum. And tighten the banjo
bolt to the specified torque.

○Turn the push rod on the master cylinder COMP,
and adjust the location of the brake pedal. And
tighten the 6mm hex nut (clockwise screw) tolock the pedal.

CAUTION : Be sure to follow the specified torque.
Torque: 13 〜 15N・m(1.3 〜 1.5 kgf・m)

CAUTION : Be sure to follow the specified torque.
Torque: 10N・m (1.0 kgf・m)○ After deciding on how to route the oil hose, cut
the oil hose. And attach it to the union on the oil
cup and to the connector on the master cylinder
COMP., and secure it with a hose clamp.

○Set the positioning of the brake pedal so it does
not interfere with the kick starter arm when you
push down the kick starter arm to the end.

○Secure the brake hose with a Tie Wrap so it does
not interfere with other parts, and cut off theexcess portion of the Tie Wrap with a nipper.
‑5‑

Sep./28/ 09

Rear-stop-lamp switch

Beware of thedirection of the hook.

○Detach the cap, diaphragm plate and diaphragmon the oil cup, and add the brake fluid up to theupper level mark on the oil cup.
CAUTION : Never produce air bubbles in thebrake fluid container by shaking thecontainer.

Ｆ○If you find that no more air is mixed, tighten the
bleeder valve to the specified torque.
CAUTION : Be sure to follow the specified torque.
Torque: 6N・m (0.6 kgf・m)○ Referring to the figure above, install theprocessed switch spring to the rear-stop-lamp
switch and to the outer grooves on the springhook.
○ On motorcycles installed with our Rear Cowl
Kit, install the rear cowl and a seat.

○ Connect the transparent bleeder hose to thebleeder valve on the rear caliper, and place asuitable cup at the other tip of the hose toreceive brake fluid.
○ Give the bleeder valve half a turn to ease it.
And repeat kicking down on the brake pedal andreleasing it until brake fluid comes down fromthe bleeder valve in sufficient amount.

○ Add the brake fluid up to the upper level mark on
the oil cup, and attach the diaphragm, diaphragmplate and cap.
WARNING : Do not get a brake disc rotor orbrake pad oil-stained. If any oil orgrease adheres to them, change
the brake pad and degrease thedisk rotor.

★ Do the work, adding new brake fluid, but
paying heed to the amounts of brake fluid in theoil cup.
○ Tighten the bleeder valve of a rear caliper.
１．Keeping the brake pedal pressed down, give
half a turn to the bleeder valve to loosen it.
And then tighten it again.
２．Release the brake pedal slowly. And after it
has returned back to the original position, leave
it untouched for a few seconds.
○ Repeat the above two procedures No. 1 and 2
until no bubble comes up from the bleeder valve.
★Please check the amount of remaining brakefluid once in a while. When the amount of fluid
has come down close to the lower level line,
add the fluid.
○When the air does not come out any more fromthe bleeder valve, operate the brake pedal tocheck if no more air is mixed.

○ In case your motorcycle is equipped with acarrier, detach a bolt which is holding thereservoir tank, install the carrier, and then, theoil cup by jointly fastening one of four bolts
holding the carrier and the reservoir tank stay.
CAUTION : Be sure to follow the specified torque.
Torque: 24 N・m (2.4 kgf・m)○ Mount the seat.
○ Finally, thoroughly wipe off dust and dirt on
every hardware.

Co.,Ltd.
3-5-16 Nishikiorihigashi Tondabayashi
Osaka Japan
TEL : 81-721-25-1357 FAX : 81-721-24-5059
URL : http://www.takegawa.co.jp‑6‑Sep./28/ 09