Instruction Manual:
5-Speed Transmission Kit for Dry-Type Clutch：０２−０４−００４２ Street：０２−０４−００４３ Super street：０２−０４−００４４ S - Touring：０２−０４−００４５ Super close
Fits:：Monkey & Gorilla
Frame No. ：Z50J-1300017〜：AB27-1000001〜 1809999
Item No.

CO・Thank you for purchasing one of our TAKEGAWA’s products. You are requested to follow the below-mentioned instructions in installing this Kit.
・Before installation, please check the contents of this Kit. Should you have any questions about the product, please kindly contact your local dealer.

Please read the following before starting the installation.

◎ This 5-Speed Transmission Kit is for exclusive use with our dry-type clutch. And please note that this Kit cannot be used with our wet-type or standard
clutch.
◎ A kick starter spindle supplied in this Kit is a B-type. So, before installation, be sure to check the frame number of your motorcycle.
◎ For the installation of the transmission, the left side crankcase needs processing, which please do correctly referring to the figure.
◎ This instruction manual refers to the work after the removal of an engine from the body, and removal and disassembly of a cylinder head, cylinder,
piston, flywheel, starter assembly, clutch assembly, primary driven gear, driven gear, oil pump and cam chain. For instructions about such removal work,
please refer to the relative HONDA’s genuine service manual for your proper work.
◎ Please note that the descriptions in this manual like illustrations and photos may differ from the actual hardware.
◎ This instruction manual and the service manual are prepared for those who have acquired basic skill and knowledge.
Therefore, technically inexperienced people or people without sufficient knowledge may not be able to install these products correctly. Improper
installation because of insufficient skill and knowledge could lead to parts breakage.

PY
Features○ This 5-speed transmission is a close-ratio type which enables the effective use of the torque band in comparison with the standard 3- or 4-speed wideratio transmission.
The Street Transmission uses a start-and-acceleration-oriented 1st gear, and the gear ratio is so designed to be user-friendly even for street use.
○ The Super street transmission has all the more sporty gear ratios with the 4th and 5th gears of the Street transmission rendered close-ratio.
○ The S-touring transmission comes equipped with wide-ratio gear for touring to suit large displacement capacity and can also be used with a standard
engine if the sprocket is changed.
○ The Super Close Transmission is designed to have highly potential gear ratios when used with a racing camshaft. Moreover, an optional gear set isavailable for each gear. Thus, you can change the gear ratio. A wide range of setting for racing purposes will become possible with the final gear
adjustment.

Gear ratio

Item No.
Kind
1st speed
2nd speed
3rd speed
4th speed
5th speed

02-04-0042
Street2.357 ( 33 / 14 )1.764 ( 30 / 17 )1.400 ( 28 / 20 )1.136 ( 25 / 22 )0.958 ( 23 / 24 )02-04-0043
Super street
2.357 ( 33 / 14 )1.764 ( 30 / 17 )1.400 ( 28 / 20 )1.136 ( 25 / 22 )1.000 ( 24 / 24 )02-04-0044
S - touring
2.357 ( 33 / 14 )1.611 ( 29 / 18 )1.190 ( 25 / 21 )0.958 ( 23 / 24 )0.807 ( 21 / 26 )02-04-0045
Super close
2.357 ( 33 / 14 )1.526 ( 29 / 19 )1.286 ( 27 / 21 )1.130 ( 26 / 23 )1.000 ( 24 / 24 )The following show the envisioned possibility of injuries to human bodies or property damage as a result of disregarding the

CAUTION following cautions.

・Please do the work correctly, using the right special tools, when needed. And apply oil or grease to the designated portions.
・In tightening bolts and nuts, be sure to use a torque wrench and tighten them to the specified torque.
・As for gaskets and packings, always use new ones. In case you continue using these parts, carefully check them for wear or damage, and when
detected, always replace these worn or damaged ones with new ones.
・The installation of this Kit changes the gear-change pattern to the return system of one down and four up. Shift gears securely only when you have
let throttle back to an original position. Shifting gears forcibly or at high engine revolution will cause the gear to get damaged or worn out.
・Before driving, always check hardware for slack in bolts and other parts or for abnormal sound. And when you notice something unusual with yourmotorcycle while riding, immediately stop riding and park it in a safe place to check what has gone wrong with it.
・When you start the engine with a kick starter, press down the starter arm firmly just when you feel some resistance on the starter arm, or at the time
the starter pinion and ratchet fit into each other. Otherwise, the gear will be damaged. And in the case of starting the engine of a racing motorcycle bymoving it forward, disengage the clutch after the gear shift, and push it forward. A violent shock to the gear may cause it to get damaged.
・Please never use this Kit together with other manufacturers’ ignition-system parts because it is likely that the gear may get damaged owing to impact
load felt at the time of starting the engine with a kick starter.
◎ 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.
◎ We shall be held free from any kind of warranty whatsoever of products other than this product if the glitch takes place on the other products than thisone after the installation and use of this product.
◎ This manual should be retained for future reference.
‑1‑

Aug./25/ 09

〜 The transmission consists of 〜
２４

１６

２２

１２

２６

CO
１８

２３
１３

２４

１７

１６ １６
１４

１６

２０

１９

００―０２―０１１７

３０

６

２０
２０

３１
３２

１９
１９

９

１５

８ ３２
３１

５

２１
２７

２５

１１ ３１

PY

２８
Ｎ

３２

１

４

３２
３１

２

７ ３１

３２

１０

３

２９

02-04-0042
No.
1
2
3
4
5
6
7
8
9
10
11

Part nameMain shaft
Counter shaft
Main shaft first gear (14T)
Counter shaft first gear (33T)
Main shaft second gear (17T)
Counter shaft second gear (30T)
Main shaft third/fourth gear (20T/22T)
Counter shaft third gear (28T)Counter shaft fourth gear (25T)
Main shaft fifth gear (24T)Counter shaft fifth gear (23T)

02-04-0043
No.
1
2
3
4
5
6
7
8
9
10
11

Part nameMain shaft
Counter shaft
Main shaft first gear (14T)
Counter shaft first gear (33T)
Main shaft second gear (17T)
Counter shaft second gear (30T)
Main shaft third/fourth gear (20T/22T)
Counter shaft third gear (28T)Counter shaft fourth gear (25T)
Main shaft fifth gear (24T)Counter shaft fifth gear (24T)

02-04-0044
No.
1
2
3
4
5
6
7
8
9
10
11

Part nameMain shaft
Counter shaft
Main shaft first gear (14T)
Counter shaft first gear (33T)
Main shaft second gear (18T)
Counter shaft second gear (29T)
Main shaft third/fourth gear (21T/24T)Counter shaft third gear (25T)Counter shaft fourth gear (23T)
Main shaft fifth gear (26T)Counter shaft fifth gear (21T)（Street）
Qty
1
1
1
1
1
1
1
1
1
1
1

Qty
1
1
1
1
1
1
1
1
1
1
1

02-04-0045

Repair part item No. In packs of23212-165-T30
123221-165-T11
123222-165-T20
123421-165-T22
123431-051-T01
123441-051-T01
123451-051-T00
123461-051-T20
123481-051-T10
123491-051-T00
123501-051-T00
1（Super Street）（Super close ratio）

No.
1
2
3
4
5
6
7
8
9
10
11

Part nameMain shaft
Counter shaft
Main shaft first gear (14T)
Counter shaft first gear (33T)
Main shaft second gear (19T)
Counter shaft second gear (29T)
Main shaft third/fourth gear (21T/23T)
Counter shaft third gear (27T)Counter shaft fourth gear (26T)
Main shaft fifth gear (24T)Counter shaft fifth gear (24T)

No.
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32

Part nameRight gear shift fork
Center gear shift fork
Left gear shift fork
Gear shift drum
Dowel pin, 4x10
Gear shift drum side plate
Gear shift drum stopper plate
Gear shift fork guide pin
Gear shift fork guide pin clip
Neutral switch rotor
Shift drum stopper arm COMP.
Shift drum stopper spring
Stopper plate setting pin
Kick starter pinion (25T)
Knock bolt, 6mm
Plain washer, 6X17X2.3
Hex bolt, 6x16
Thrust washer, 14mm
Thrust washer, 13.5mm
External circlip, 17mm
Spline washer, 17mm

Qty
1
1
1
1
1
1
1
1
1
1
1

Repair part item No. In packs of23212-165-T30
123221-165-T11
123222-165-T20
123421-165-T22
123431-165-T00
123441-165-T01
123451-165-T00
123461-165-T00
123481-165-T00
123491-165-T01
123501-165-T00
1

Common Parts

Repair part item No. In packs of23212-165-T30
123221-165-T11
123222-165-T20
123421-165-T22
123431-051-T01
123441-051-T01
123451-051-T00
123461-051-T20
123481-051-T10
123491-165-T01
123501-165-T00
1（S-Touring）
Qty
1
1
1
1
1
1
1
1
1
1
1

※A component marked “N” shows a genuine part.

Repair part item No. In packs of23212-165-T30
123221-165-T11
123222-165-T20
123421-165-T22
123431-181-T00
123441-181-T00
123451-181-T10
123461-181-T10
123481-181-T10
123491-181-T00
123501-181-T00
1

Qty
1
1
1
1
4
1
1
3
3
1
1
1
2
1
1
1
1
1
1
5
5

Repair part item No. In packs of
00-02-0014
100-02-0015
100-02-0016
100-02-0049
00-02-0018
24411-051-T01
00-02-0048
24263-165-T00
00-02-0118
00-02-0025
24435-GEF-T00
00-02-0054
28211-165-T20
00-02-0013
00-02-0050
00-00-0032
00-02-0047
00-02-0055
00-02-0005
00-02-0023

5
1
1
3
1
1
1
1
1
1
1
1
3
1
1
5
5

※ 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‑Aug./25/ 09

〜 On processing 〜
CAUTION

Always work with gloves on to protect your hands. Otherwise, you may suffer injuries.

Left side crankcase

CO〇Fold down the circled portion on the left side crankcase with a plier, andrasp the circled portion with a file or a hand grinder. Then wash the left
side crankcase with water.
※ Cover the bearings with a tape not to get any dirt, dust or chips intothem.
※ Work with gloves on lest you should cut your hands with edges of thecase.

Rasp here.

PY

Rasp the shaded area.

mm

About 7 mm

Ab
out
18

〇 In case a kick starter pinion and a left side crankcase interfere witheach other on motorcycles with frame Nos from AB27- onwards, cut off
the circled portion until the gear does not touch it any more.
※ Cover the bearings with a tape not to get any dirt, dust or chips intothem.
※ Work with gloves on lest you should cut your hands with edges of thecase.

Rasp here.

Gearshift arm
Rasp the shaded area.

〇 Rasp the tip of the gearshift arm.
※ Work with gloves on lest you should cut your hands with edges of theshift arm.

Full scale‑3‑Aug./25/ 09

〜 On installation 〜
１．Apply grease to the lips of the oil seal of the left side crankcase shiftspindle. Apply oil to the bearings of the right and left side crankcases.
And place the left side crankcase on the pedestal. Apply oil to therubbing surfaces of the gears on the sides of the mainshaft and４．Degrease the mating surfaces of the right and left side crankcases.
And set a dowel pin and attach new gaskets. Put together the rightand left side crankcases, and check that the they fit together closely.
With the left side crankcase up, place the bolts, and tighten first thosecountershaft. And mesh together the gears of the mainshaft andcountershaft, and fit the hook of the shift fork into the grooves on thegear.

placed in the middle, and then those placed outside but diagonally andalternately.
Specified torque: 10 N・m (1.0 kgf・m)

CO

Dowel pin

Shift drumCounter shaft

GasketMain shaft

２．Install into crankcase the main shaft, counter shaft and shift drum all
together as a unit.
※ Do above installation with the transmission in neutral, or at theposition where the neutral switch and switch rotor mesh together.
※ Never forget to install the thrust washer. As the stock washer is not

５．Put together the right and left side crankcases.
With the left side crankcase up, place the crankcase bolts on thePYcrankcase, and tighten them diagonally in a few steps to the specified
torque.
Specified torque: 10 N・m (1.0 kgf・m)

to be used, remove it.
※Install the shaft with care so the lip of the countershaft oil seal may
not turn up.

Neutral switch
rotor

Neutral switch

６Ｖ

６．Setting the round corner of the shift drum side washer to face toward
the shift drum, tighten a hex bolt to the specified torque.
Specified torque: 12 N・m (1.2 kgf・m)
Washer３．
Remove, from the kick starter spindle, a 17mm washer, 20mm set ring,
starter drive ratchet, 20mm set ring, 20mm thrust washer and starter
pinion, in this order.
Install the starter pinion included in the Kit onto the kick starter spindle,
and install the above-mentioned parts in the opposite order ofHex bolt

removal.
Install the rubber plug.

Rubber plug

Meshing its friction spring with grooves in the left side crankcase,attach the starter spindle to the left side crankcase.
※ Apply engine oil to the starter pinion and starter spindle.
‑4‑Aug./25/ 09

７．Turn around the crankcase so the right side crankcase faces
upwards. And install the kick starter spring and kick spring retainer tothe starter spindle. And fit the spring end into the case with a click.
And install the external circlip.
※ Be careful not to get your fingers caught when fitting the spring into
the case.

CO

１１．Place the spring in the stopper arm, fit them into the stopper plateon the case, and tighten the bolt to the specified torque.
Specified torque: 10 N・m (1.0 kgf・m)※ Be careful not to get your fingers caught when fitting the spring
into the case.
Stopper arm

Fit the spring end into the case with a click.

１２．Turning the mainshaft with hands, turn the knock bolt on the
stopper plate with a socket wrench, and check if the gears canshift smoothly.
Check that there is some free play in the mainshaft andcountershaft in the direction of thrusting.
※ Do not turn the shift drum forcibly.

Retainer

Circlip

８．Fit four dowel pins and two stopper plate setting pins into the shift
drum, and install the processed gear shift arm onto crankcase.
※Apply engine oil to the sliding surface of the shift spindle and gear
shift arm.
※ Apply grease to the lip of the oil seal for the left side crankcase shiftspindle.
Setting pin

Dowel pin

Shift arm

PY

◎ Reinstall back the removed parts with reference to the service manual.
Shift the transmission into NEUTRAL, and start the engine. Then checkevery component for oil leak. If nothing is wrong, do a test run at slow
speed in a safe place to check how the transmission works.

９．Install the shift-drum side plate on the shift drum, meshing the holeson the shift drum side plate with the shift drum setting pin.
Side plate

１０．Fit the shift drum stopper plate into the shift drum setting pin,
keeping the marking on the plate visible. And then, apply thread lockcement to the thread of the dowel bolt, and tighten it to thespecified torque.
Specified torque: 16 N・m (1.6 kgf・m)

Apply the screw locking agent.
Laser marking‑5‑Aug./25/ 09

Transmission assembly drawing:
Main shaft assemblyCO
M5 gearM3 / M4 gear
M2 gearM1 gearMain shaft

14mm Thrust washer

PY

17mm External circlip

17mm Spline washer

17mm Spline washer

Counter shaft assembly
C1 GearCounter shaft

C2 GearC3 GearC5 GearC4 Gear13.5mm Thrust washer

17mm External circlip

17mm External circlip
17mm Spline washer

17mm Spline washer

Co.,Ltd.
3-5-16 Nishikiorihigashi Tondabayashi Osaka Japan
TEL : 81-721-25-1357‑6‑

FAX : 81-721-24-5059

URL : http://www.takegawa.co.jp
Aug./25/ 09