Special Crankcase set for Complete engine (4SMS)(Takegawa original stud pattern)

CO０１―００―００２８ (For 123cc only)
０１―００―００２９ (For 138cc only)
０１―００―００４１ (For SCUT 148cc only)Thank you for purchasing one of our products.
This crankcase set made for our original complete engine only. There are up graded durability and liability from former (4SM) crankcase set. Our special
clutch kit and generator cover is compatible with Monkey (Z50J-2000001 and up) This crankcase capable up to 148cc with wider stud pattern. You can build
complete engine based on this crankcase. Please refer our parts catalog or ask our dealer for more information.
◎ Please note that the descriptions in this manual like illustrations and photos may differ from the actual hardware.

Features○ Oil pump drives by directly from crankshaft so that larger volume of oil delivered than stock chain drive type.
○ Crankcase has additional oil line to cool the piston and cylinder from inside.
○ The transmission shaft holds by ball type bearing.
○ Bearing hold plate is cooperated. (5 or 6 speed transmission only)

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Read all instructions before starting the installation.

◎ You may need more parts to using this crankcase kit.

◎ You need to have specially made main shaft and counter shaft of the transmission need for this crankcase. (P.3 for reference)◎ 01-00-0041 for SCUT 148cc only, not for 123cc or 138, unless boring.
◎ Clutch cover must use current special clutch kit only. (Old type special clutch will not fit)
◎ This case for our complete engine only, stock or even our kit parts will not fit. Please ask our dealer for more information.
CAUTION The following show the envisioned possibility of injuries to human bodies or property damage as a result of disregarding the following cautions.
・This product is designed for exclusive use on the closed course. Never use on public roads.
・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.)
・As some products and frames have sharp-pointed or protruding portions, please work with your hands protected. (Otherwise, you will suffer injuries.)
・Always use new gaskets and sealings. (Don not over use or worn parts, it may damage the engine)
WARNING The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the following cautions.
・Those who are technically unskilled or inexperienced are required not to do the work.
(Improper installation due to unskilled technique or lack of knowledge could lead to parts breakage and consequently to accidents.)
・Before doing work, place the motorcycle on level ground to stablize the position of your motorcycle for safety's sake.
(Otherwise, your motorcycle could fall down and injure you while you are working.)
・If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in an enclosed area.
・Gasoline is extremely flammable and is explosive under certain conditions. Keep out of reach of children.
・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.)・ Use specified or genuine Takegawa parts only. Never use and mixed with other manufactures parts.
・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.)
・When you notice something abnormal with your motorcycle while riding down a road, stop riding immediately and park your motorcyle in a safelace. (Otherwise, the abnormaility could lead to an accident.)
・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.)
・Check or perform maintenance of parts correctly according to the procedures in the instruction manual or a service manual.
(Improper checking or maintence could lead to an accident.)
・Always use high-octane gasoline. (Otherwise, troubles such as engine knocking may cause accidents.)◎ 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.
‑1‑Jul./31/ 13

〜 Kit contains 〜
１

CO
２

No.
1
2
1
2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25

１２

１３

３
４

２０ ２２

２４
６
１９

５

２１
７

２３

１４ １５ １６

２５

１７ １８

８ ９ １０ １１

PYPart nameRight side crankcase assembly (123cc)
Left side crankcase assembly (123cc)
Right side crankcase assembly (138cc)
Left side crankcase assembly (138cc)
Right side crankcase assembly (148cc SCUT)
Left side crankcase assembly (148cc SCUT)
Oil pump COMP.
Oil pump drive gear
Flat head screw, M6 x 35
Flat head screw, M6 x 45
Cam chain guide roller COMP.
Cam chain guide roller bolt
Plain washer, 6.5 x 16 x 2.6
Dowel pin, 10 x 14
Dowel pin, 8 x 12
Crankcase gasket
Right side crankcase cover gasket
Flange bolt, M6 x 45
Flange bolt, M6 x 60
Flange bolt, M6 x 65
Flange bolt, M6 x 70
Copper sealing washer
Mainshaft bearing hold plate
Flat screw, M6 x 12
Countershaft bearing hold plate
Flat screw, M5 x 10
Shift drum stopper arm COMP.
Shift drum stopper spring
Shim ring, 17 x 30 x 1

Qty
1
1
1
1
1
1
1
1
1
2
1
1
1
2
2
1
1
2
2
4
1
1
2
2
1
3
1
1
1

Repair Part Item No.

In packs of
1
1
1
00-01-0271
1
1
00-01-0272
1
00-01-0119
115342-GEF-T01
100-00-0155
400-00-0157
400-01-0122
1
00-01-0123
1
00-01-0118
200-01-0124
200-00-0153
2
1
01-13-0609
100-00-0603
400-00-0604
400-00-0605
400-00-0188
4
00-01-0029
400-01-1040 (bolt set)
1set
00-00-0384
200-01-1041 (bolt set)）
1set
00-00-2778
4
1
00-02-0025
1
00-02-0152
00-01-0307
100-01-0270※ Please order repair parts with the Repair Part Item No.
Without the repair part item No., we may not be able to provide the correct parts.
Some parts are only available as a set. Please order them with the set number.

Co.,Ltd.
3-5-16 Nishikiorihigashi Tondabayashi Osaka Japan‑2‑

TEL : 81-721-25-1357 FAX : 81-721-24-5059 URL : http://www.takegawa.co.jp
Jul./31/ 13

rev.Nov./01/ 14

Transmission conversion parts (optional)● Con’ rod stopper
Item No.:00-01-01

Counter / main shaft set for wet special clutch
4 speed01-00-0017 (Takegawa close transmission only)

5 speed01-00-0005☆ Special Tools

5 speed (TAF) 02-04-0093
6 speed01-00-0007

5 speed01-00-0004

COCounter / main shaft set for dry special clutch

5 speed (TAF) 02-04-0094
6 speed01-00-0006● Lock nut wrench
Item No.:00-01-021 for 12.7 mm (1/2)
00-01-022 for 19.5 mm (3/8)

Transmission kit

Applicable clutch kit

Wet special clutch

Dry special clutch

Transmission type

Item No.

Super street 5 speed (TAF)

02-04-0247

S-touring (TAF)

02-04-0083

6 speed close ratio

02-04-0095

Super street 5 speed (TAF)

02-04-0246

S-touring (TAF)

02-04-0084

6 speed close ratio

02-04-0096

PY● Flywheel puller
Item No.:00-01-031● Universal holder
Item No.:00-01-1002● Puller adapter
Item No.: 00-01-1027● Crank shaft installer & Puller set
Item No.:00-01-1008(3-point support crank only)‑3‑Jul./31/ 13

Please check the applicable clutch cover kit.
Clutch cover type

CO

Applicable
・Good

○

Die cast

・Good○

Current model

Wet type
clutchNote

Sand cast 1

Old type

Sand cast 2

Current model

Sand cast 1
Dry type
clutch・Interface with oil pump,cannot install.

×

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×

・Interface with oil pump,cannot install.
・Non oil filter type.

・Good

○

・Interface with oil pump,cannot install.

×

Old type×

Sand cast 2‑4‑・Interface with oil pump,cannot install.
・Forward type oil filter.

Jul./31/ 13

COInstallation Procedures◎Please note: Illustrations and photos may vary from actual hardware.

● Installation for main shaft bearing hold pate○Install this bearing hold pate for 5 or 6-speed transmission ONLY.
Caution:Do not use with 4-speed transmission.
Flat head screw, M6 x 12
Torque: 8 N・m (0.8 kgf・m)●Assembly of Crankshaft(In the Case of Three-Point-Support Crankshaft)○ Holding the threaded shaft, turn the installer collar nut
counterclockwise so the crankshaft comes up.

○Attach the plate of the crankshaft puller set included in the tool
set to the right side crankcase with a 6x20 screw.

Apply thread lock cement

Mainshaft bearing
Hold pate
Bearing

Sectional view

Plate

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☆ Crankshaft installer & puller set:

R.Crankcase○ Install shift return spring pin on the R side crankcase to thepecified torque.
Shift return
spring pin

Takagawa P / N : 00-01-1008∴ When the crankshaft bearing is in close contact with thecrankcase, the crankshaft is already at the desired place.
Caution:Pulling up the crankshaft further upward even after
the bearing has come in close touch with thecrankcase, the crankcase will get damaged.
Therefore, do the work with care.
○ Install plane washer and guide roller.

○ Install firmly the threaded shaft to the crankshaft, and then an
installer collar and installer nut.
Threaded shaft

Screw, 6 x 20

Washer

Installer nut

Installer collar
Plate
R.Crankcase
Crankshaft

Caution: Apply the specified torque.
Torque: 13 N・m (1.3 kgf・m)

Caution: Apply the specified torque.
Torque: 13 N・m (1.3 kgf・m)☆ Shift return spring pin
Takagawa P / N : 00-01-0273

‑1‑

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Installation Procedures○Install cam chain tensioner, pivot and roller to the specified torque.
Cam chain tensioner bolt

Cam chaintensioner arm
Guide roller

Bolt

Caution: Apply the specified torque.
Torque: 16 N・m (1.6 kgf・m)☆Cam chain tensioner arm
Takagawa P / N : 00-01-0274☆ Cam chain tensioner roller
Takagawa P / N : 00-01-0275☆ Cam chain tensioner pivot
Takagawa P / N : 00-01-0276○ Install push rod tensioner spring, washer with sealing washer tothe specified torque.

Cam chaintensioner spring
Cam chain tensioner
push rod hed

Sealing washer
Sealing bolt

Cam chain tensioner
push rod COMP.

Caution: Apply the specified torque.
Torque: 22 N・m (2.2 kgf・m)☆ Cam chain tensioner spring
Takagawa P / N : 00-01-0277☆Cam chain tensioner push rod COMP.
Takagawa P / N : 00-01-0278☆ Cam chain tensioner push rod hed
Takagawa P / N : 00-01-0279☆ Sealing bolt
Takagawa P / N : 00-01-0280☆ Sealing washer
Takagawa P / N : 00-01-0281
‑2‑

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Installation Procedures●Install transmission

4-speed transmission and wet special clutch

・Mainshaft

M2 gearM4 gearM3 gear○ Assemble main shaft and counter shaft with circlip○ Apply molybdenum solution to every gear and assemble gears.
○ In installing the thrust washer, install its curved portion in the
direction where the heavier load is on the thrust washer.

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Spline washer, 17 mm

Mainshaft M1 gear

Circlip, 17 mm

Spline washer, 17 mm

・Countershaft

C1 gearC2 gearC3 gearC4 gearCountershaft

C1 gear collar

Shim ring, 12 x 18
Thrust washer, 12 mm

Circlip, 17 mm
Spline washer B

Spline washer, 17 mm
‑3‑

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Installation Procedures・Main shaft
for wet-type clutch

5-speed transmission and wet special clutch○ Assemble main shaft and counter shaft with circlip

M5 gearM3/4 gear○ Apply molybdenum solution to every gear and assemble gears.

M2 gearMainshaft M1 gear

○In installing the thrust washer, install its curved portion in the
direction where the heavier load is on the thrust washer.

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Spline washer, 17 mm

Circlip, 17 mm

Spline washer, 17 mm

・Countershaft

C3 gear C4 gear

C1 gearC2 gearC5 gearCountershaft

Thrust washer S※ For TAF series transmission
Thrust washer, 17mm

Shim ring, 12 x 18
Thrust washer, 12 mm

Circlip, 17 mm

Circlip, 17 mm
‑4‑
１４） .

Spline washer, 17 mm

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Installation Procedures・Main shaft

5-speed transmission and wet special clutch

for dry-type clutch○ Assemble main shaft and counter shaft with circlip※ In installing, beware of the direction in which the M1 gear is to be installed.

○ Apply molybdenum solution to every gear and assemble gears.

M5 gear○In installing the thrust washer, install its curved portion in the
direction where the heavier load is on the thrust washer.

M3/4 gear

M2 gearM1 gearMainshaft

PY
CollarSpline washer, 17 mm

Spline washer, 17 mm

・Countershaft

Circlip, 17 mm

C3 gear C4 gear

C1 gearC2 gearC5 gear・Countershaft

Thrust washer S※ For TAF series transmission
Thrust washer, 17mm

Shim ring, 12 x 18
Thrust washer, 12 mm
Circlip, 17 mm

Circlip, 17 mm

Spline washer, 17 mm
‑5‑

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Installation Procedures・Mainshaft

6-speed transmission and wet special clutch

for wet-type clutch

M6 gearM5 gearM3/4 gear

M2 gear○ Assemble main shaft and counter shaft with circlip○ Apply molybdenum solution to every gear and assemble gears.
○In installing the thrust washer, install its curved portion in the
direction where the heavier load is on the thrust washer.

・Countershaft

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Thrust washer S

C5 gearC1 gearThrust washer S

Mainshaft M1 gear

Circlip, 17 mm

Spline washer, 17 mm

C3 gear C4 gear

C6 gearC2 gearShim ring, 12 x 18

Thrust washer, 12 mm

Spline washer, 17 mm

Circlip, 17 mm
Circlip, 17 mm
Thrust washer, 17 mm
Splinewasher,
17 mm
Spline washer, 17 mm
‑6‑

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Installation Procedures・Mainshaft
for dry-type clutch

6-speed transmission and wet special clutch○ Assemble main shaft and counter shaft with circlip※ In installing, beware of the direction in which the M1 gear is to be installed.

○ Apply molybdenum solution to every gear and assemble gears.

M1 gear○In installing the thrust washer, install its curved portion in the
direction where the heavier load is on the thrust washer.

M5 gearM3/4 gear

M6 gearM2 gear

PY
CollarMainshaftCirclip, 17 mm

Spline washer, 17 mm

Thrust washer S・Countershaft

C3 gearC5 gearC1 gearC4 gearC6 gearThrust washer S
Circlip, 17 mm

Thrust washer, 17 mm
Spline washer, 17 mm

C2 gearShim ring, 12 x 18

Thrust washer, 12 mm

Spline washer, 17 mm
Circlip, 17 mm
Spline washer, 17 mm
‑7‑

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Installation Procedures●Transmission and crankcase assembly○ Apply engine oil to each gear.
○ Join together the mainshaft and countershaft to which gears
have been installed. After aligning the shift forks with shifter gear
grooves, attach the shift drum to the transmission.

○ Attach the drive ratchet to the kick starter spindle, and secure itwith a set ring.

○ Attach a new gasket to the left side crankcase.

Set ring

Shift drumCountershaft

PY○ Attach the kick starter spindle to the left side crankcase, andinstall the washer then.

Mainshaft○ Install transmission assembly in Neutral gear position.
Shim ring, 12 x 18 x 0.2
Thrust washer, 12 mm

Washer○Degrease well the mating surface of the left side crankcase, andattach dowel pins.
○ Install the kick starter spindle aligning its friction spring end withthe groove in the left crankcase.
Set ring

SpindleWasherStarter pinion

NEW○Install crank shaft (2 point crank) and right crankcase over theleft crankcase.

○Install and tighten the crankcase bolt in a crisscross pattern in 23 steps.
∴ Only 6x70 bolt tight with copper sealing washier.

６×６５

６×６５

６×６０
６×６０

６×４５

６×６５
６×６５ ６×７０ Copper sealing washierCaution: Apply the specified torque.
Torque: 10 N・m (1.0 kgf・m)☆ Kick starter spindle kit
Takagawa P / N : 02-04-0011

‑8‑

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Installation Procedures○Install the washer and bolt to the shift drum. Then tighten the bolt
to the specified torque.
Install the rubber plug.
Washer○Install the return spring and retainer onto the kick starter spindle.
Install the spring ends onto the retainer and crankcase lug whileturning the spindle counterclockwise.

○ Attach the collar and return spring to the gearshift arm.
Shift arm spring
Shift return spring
Hook
CollarBolt

Rubber plug

Caution: Apply the specified torque.
Torque: 10 N・m (1.0 kgf・m)○ Install neutral switch contact and tighten with plate.
Neutral switch

Gearshift spindle

PY
Retainer○ Attach the external circlip to the spindle.

Plate○ Install the gearshift arm onto the crankcase.

Circlip○ For 6-speed transmission, modify the gearshift arm as shown.

Do not grind the edge
Cut straight,
Keep sharp edge
O ring☆Collar, 12.2mm
Genuine Honda parts number : 24639-035-000☆ Gearshift return spring
Genuine Honda parts number : 24651-035-000○ Locate two kinds of drum pins on the shift drum.
Dowel pin

Close-ratio 4-speed

Setting pin

7.5 〜 8mm
actual size

Bolt
‑9‑

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Installation Procedures

Dowel pin
Setting pin

Close-ratio 5-speed∴ 1 setting pin type・Set the drum pin into the hole on the stopper plate. And apply a thincoat of thread lock to the dowel bolt, and tighten the dowel bolt to○Attach the shift drum stopper spring and shift drum stopper tothe crankcase, and tighten them to the specified torque.

the specified torque.

Stopper arm

Caution: Apply the specified torque.
Torque: 16 N・m (1.6 kgf・m)

Apply thread lock cement

Setting pin
Dowel pin

∴ 2 setting pin type

Apply thread lock cement
Laser
marking

Dowel pin

Close-ratio 6-speed

Apply thread lock cement

Side plate

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Caution: Apply the specified torque.
Torque: 10 N・m (1.0 kgf・m)

Close-ratio 5-speed∴ Check whether the gear is installed all right or not.
○While keeping the mainshaft rotating, check how the gear is
installed by rotating the dowel bolt on the stopper plate with awrench.

Setting pin○ Attach the shift drum side plate to the drum pin.

Close-ratio 4-speed
・Set the stopper platewith the concave
portion in the centerto face outward.

Close-ratio 6-speed
・Set the stopper platewith the convex
portion in the centerto face outward.

∴Check that there is some free play in the end thrust in the mainshaft
and countershaft.
∴ Do not rotate the shift drum forcibly.

‑10‑

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Installation Procedures● Install oil pump

○ Locate a conical spring washer and then a lock nut.

○Fit the hook of the lock washer into the concave portion of thelock nut.

○Install kitted shim ring and oil pump gear groove faced outside.
Drive gear

GrooveShim ring○ Install primary drive gear.

Lock nut

Drive gear

Lock washer

Conical spring washer(Beware of the direction)
Hook

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∴ Locate the conical washer, being careful of the direction of theconical spring washer.
○ Install the connecting rod stopper, included in the tool set, to theconnecting rod.

Caution:if the hook on the lock washer does not fit in the
concave of the lock nut, turn the lock nut in the
direction of tightening so the hook fits right into theconcave.
○ Install dowel pin (8x12) on the right crankcase.

Connecting
rod stopper

Gasket☆ Connecting rod stopper
Takagawa P / N : 00-01-011○ Tighten the lock nut to the specified torque using the lock nut○ Install oil pump with flat head screw to the specified torques.

wrench included in the tool set.

Caution: Apply the specified torque.
Torque: 41 N・m (4.0 kgf・m)

Caution: Apply the specified torque.
Torque: 9 N・m (0.9 kgf・m)

‑11‑

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Installation Procedures● Clutch installation○ Install a generator plate, and tighten the flat screws.

○ Refer the clutch kit installation manual, and install clutch cover.
※ R cover must be current model; our old R cover will not fit.

● Cylinder installation● Generator cover installation○ Install generator cover, use specified bolt (M6x45) as shown to
the specified torque.
6 x 45○ Install cam chain (chain link may different by the strokes)○ Install grommet and connect neutral switch.
Grommet○Refer the cylinder kit installation manual.

● Cylinder Head installation○ Refer the cylinder head kit manual.

● Ignition system installation○ Fix O-rings onto two locations.

PY◎ Refer the installation manual of ignition system.

○ Fix the woodruff key to the crank shaft.
○Clean any oil from the crankshaft taper. Then install the woodruff
key, flywheel and nut to the specified torque.

Caution: Refer crankshaft manual.

‑12‑

Caution: Apply the specified torque.
Torque: 10 N・m (1.0 kgf・m)