TAF 5-Speed Transmission Kit Instruction Manual
Product number

02-04-0071 S-Touring
02-04-0075 Super Street

Monkey/Gorilla (Z50J-1300017 ～ 2699999)(AB27-1000001 ～ 1899999)
Adaptation modeland chassis numbers Monkey BAJA
(Z50J-1700001 ～ )CD50(CD50-1300001 ～ 1330600)

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.
◎ This product installation and use, when a problem occurs to after market goods, guarantee other than this product, also can notassume 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.
◎ This 5-speed transmission is a close ratio type which enables the effective use of torque band in comparison with the standard 3・4
open ratio transmission.
◎ This kit is for use with a type B kick starter spindle. Before installation, be sure to check your frame No.
◎ Installation of the transmission needs the processing of the left side crankcase. Do the work correctly, referring to the figure.
◎ This instruction manual covers the installation work only after the procedures of the engine removal from the body, and removal anddisassembly of a cylinder head, cylinder, piston, flywheel, starter assembly, clutch assembly, primary driven & drive gears, oil pumpand cam chain. For instructions about the removal work, please refer to the relative genuine service manual for you to work properly.

CO～ feature ～○ This return type transmission kit is increased the durability compared to our current 5-speed transmission.
○ The center gear shift fork is also increased the durability.
○ In order to increase the durability of each gear, the stroke of the shift fork is designed to be shorter and quick so that the gear
can be also designed to be thicker.
○ This kit includes a right side crankcase cover gasket and a center crankcase gasket.
○ Adopted a new inverted taper dog shape in the meshing part of each gear to further improve the gear disengagement prevention effect.
Item No.
Kind
1st speed
2nd speed
3rd speed
4th speed
5th speed

Gear Ratio
02-04-0071
S-Touring
2.357（33/14）
1.611（29/18）
1.190（25/21）
0.958（23/24）
0.807（21/26）

02-04-0075
Super Street
2.357（33/14）
1.764（30/17）
1.400（28/20）
1.136（25/22）
1.000（24/24）

PY

This 5-Speed Transmission Kit is compatible with a stock clutch, heavy duty clutch, and Special Clutch Kit.

☆ Cautions for Installation ☆

○ Remove all the stock washers, and use the supplied thrust washers only.
○ For the installation of this Kit onto the 12V Monkey, Monkey BAJA, inside of the left side crankcase needs processing.
CautionWhen the handling of ignoring this display, property damage and human shows the assumption of what injury.

■ Do the work correctly using right special tools when required. And be sure to apply engine oil or grease to the specified portions.
■ Be sure to tighten bolts and nuts with a torque wrench to the specified torque.
■ Always use new gaskets and seals. And as for other parts to be reused, carefully check them for wear or damage, and in case wear ordamage is detected, always replace these worn or damaged parts with new ones.
■ The installation of this Kit will change the gear-change pattern to the return system of 1-down-4-up. Change gear only when you have
let throttle fully back to idle position. Changing gears forcibly or at high engine revolutions will cause the gear to get damaged orworn out.
■ Before riding, always check every hardware like screws and nuts for slack and for unusual sounds. When you notice something unusualwith your motorcycle while riding down a road, immediately stop riding and check what has gone wrong with the motorcycle.
■ When you start the engine with a kick starter, press down the starter arm hard at the time you feel some resistance on the starter
arm, or at the time the starter pinion and rachet fit into each other. Otherwise, the gear will be damaged. And in the case of a
racing motorcycle, if you start the engine by moving it forward, disengage the clutch after the gear change, and push it forward.
A violent shock to the gear may cause gear to get damaged.
■ Please never use this Kit in combination with other manufacturers ignition-system parts, because it is likely that,if ignition-systemparts of other manufacturers' make are used, the gear may get damaged owing to impact shock felt at the time of starting the engine
with a kick starter.
◎ Please note. Performance up, the design change, the product and the price in the cost up, etc. are subject to change without notice.
◎ Keep this manual stored until this product is discarded.
CONTACT Address : 3-5-16 Nishikiorihigashi Tondabayashi Osaka JAPANTEL: +81-721-25-1357 FAX:+81-721-24-5059 e-mail:english@takegawa.co.jp URL http://www.takegawa.co.jp
Please contact with your name and country name provided. (Only English please)2020.9.302-04-0071,0075

/5Product content

242216271814241716 1616131920

1120423123120

1930

CO197156 30

3 302131319529253128
N30

31358210126※ A component marked “N” shows a genuine part.
02-04-0071（S-Touring）
Number12
34
5678910

Product content
Main shaft（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）Counter shaft

Number12345678910

Product content
Main shaft（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）Counter shaft

Quantity
1111111111PY
3432

Common Parts

Item Number
00-02-0341
23421-086-T01
23431-086-T10
23441-086-T10
23451-086-T10
23461-086-T1023481-086-T1023491-086-T10
23501-086-T10
23221-165-T2102-04-0075（Super Street）
Quantity
111111111133

Item Number00-02-0341
23421-086-T01
23431-GEL-T1123441-GEL-T10
23451-GEL-T11
23461-GEL-T11
23481-GEL-T11
23491-GEL-T11
23501-GEL-T10
23221-165-T21

Number11121314151617181920212223242526272829303132333435

Product content
Thrust washer,13.5mm
Right gear shift fork
Left gear shift fork
Center gear shift fork
Gear shift drum
Shift drum pin,4x10Gear shift drum side plate
Gear shift drum stopper plate
Gear shift fork guide pin
Gear shift fork guide pin clip
Neutral switch rotor
Gear shift drum stopper arm
Gear shift drum stopper spring
Stopper plate setting pin
Kick starter pinion（25T）
Thrust washer, 14mm
Knock bolt, 6mm
Gear shift drum side washer
Hex bolt, 6x16
Spline washer, 17mm
External circlip, 17mm
Right crankcace cover gasket
Crankcace gasket（ 6V）
Crankcace gasket（12V）
Thrust washer S, 17mm

※ 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.
2020.9.302-04-0071,0075

/5Quantity
1
1
1
1
1
4
1
1
3
3
1
1
1
2
1
1
1
1
1
4
5
1
11
1

Item Number00-02-0055
00-02-0014
00-02-0016
24231-181-T02
24301-181-T2000-02-0049 (5 pcs)
00-02-0018
24411-051-T01
00-02-0048 (3 pcs)
24263-165-T00
00-02-0118
00-02-0025
24435-GEF-T00
00-02-0054
28211-165-T20
00-02-0047
00-02-0013
00-02-0050
00-00-0032 (3 pcs)
00-02-0023 (5 pcs)
00-02-0005 (5 pcs)
00-01-0095
00-01-1032
00-01-0096
00-02-0024 (2 pcs)

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

Left side crankcase■ Fold down the circled portion on the left side crankcase with aplier, and rasp 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
into them.
※ Work with gloves on lest you should cut your hands with edges ofthe case.

■ In case a kick starter pinion and a left side crankcase
interfere with each other, 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 orchips into them.
※ Work with gloves on lest you should cut your hands withedges of the case.

Rasp the shaded area.

COAbout18mRR■ Mounting procedure

Rasp here.

RRasp here.

About 7mmm

※ Please refer to the genuine service manual if the detail is not mentioned method and the specified torque.
3.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 kickstarter spindle,and install the above-mentioned parts in theopposite order of removal.

1.Apply grease to the lips of the oil seal of the left side
crankcase shift spindle. Apply oil to the bearings of the rightand left side crankcases.
And place the left side crankcase on the pedestal. Apply oil tothe rubbing surfaces of the gears on the sides of the mainshaft
and countershaft. And mesh together the gears of the mainshaft
and countershaft, and fit the hook of the shift fork into thegrooves on the gear.
Shift drumCounter shaft
Main shaft

PY

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.

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
the position where the neutral switch and switch rotor mesh
together.
※ Never forget to install the thrust washer. As the stock washer
is not to be used, remove it.
※※ Install the shaft with care so the lip of the countershaft oil
seal may not turn up.

4.Degrease the mating surfaces of the right and left side
crankcases.And set a dowel pin and attach new gaskets.
Put together the right and left side crankcases, and check thatthe they fit together closely.Install the crankcase bolts withthe left crankcase face up.
Dowel pin

GasketSwitch rotor

Neutral switch

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■ Mounting procedure※ Please refer to the genuine service manual if the detail is not mentioned method and the specified torque.

5.Tighten with the specified torque in a diagonal line outward fromthe center in 2-3 steps.
Note: Be sure that you protect specified torque.
Crankcase bolt

Torque：10N・m（1.0kgf・m）

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

Shift arm

CO

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.

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

Note: Be sure that you protect specified torque.
Hex bolt

Torque：12N・m（1.2kgf・m）
WasherHex bolt

Install the rubber plug.

Rubber plug

10.Fit the shift drum stopper plate into the shift drum setting
pin,keeping the marking on the plate visible. And then, apply
thread lock cement to the thread of the knock bolt, and tighten
it to the specified torque.
Recommend LOCTITE:241
Note: Be sure that you protect specified torque.
Knock bolt

PY

Torque：16N・m（1.6kgf・m）

Apply the screw locking agent.
Laser marking

11.Place the spring in the stopper arm, fit them into the stopper
plate on the case, and tighten the bolt to the specified torque.
Note: Be sure that you protect specified torque.
Stopper arm bolt

Torque：10N・m（1.0kgf・m）
Stopper arm

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

Fit the spring end into the case with a click.
12.Turning the mainshaft with hands, turn the knock bolt on thestopper 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.
◎ Reinstall back the removed parts with reference to the service
manual.
Shift the transmission into NEUTRAL, and start the engine. Thencheck every component for oil leak. If nothing is wrong, do atest run at slow speed in a safe place to check how thetransmission works.

RetainerCirclip

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Transmission assembly drawing:

Main shaft assembly
M5 gearM3/M4 gear
M2 gearM1 gearMain shaft

COThrust washer, 14mm

Thrust washer S, 17mm

Spline washer, 17mm

External circlip, 17mm

PY

Counter shaft assembly

C1 gearC2 gearC3 gearC5 gearCounter shaft

C4 gearThrust washer, 13.5mm

External circlip, 17mm
Spline washer, 17mm

2020.9.3

Spline washer, 17mm

02-04-0071,0075

/5External circlip, 17mm