SS5-Speed Transmission Kit Instruction Manual
02-04-0200 (Street)
Product number 02-04-0201 (Super street)
02-04-0202 (S-Touring)

Adaptation model

Monkey/Gorilla (Z50J-1300017 ～ )(AB27-1000001 ～ 1899999)

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 anyresponsibility 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.
◎ Product may have edges or protrusions. Be sure to wear working gloves.
(Please wear work gloves when working, even if a photo in this article show without work gloves.)◎ 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 wide-ratio transmission.
The Street Transmission uses a start-and-acceleration-oriented 1st gear, and the gear ratio is so designed to be user-friendly evenfor street use.
◎ The Super street transmission has all the more sporty gear ratios with the 4th and 5th gears of the Street transmission renderedclose-ratio.
◎ 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 genuine service manual for your proper work.
◎ Before riding, check the all transmission, gear and drive train that move and operate smooth and properly.

COThis 5-Speed Transmission Kit is compatible with a stock clutch, heavy duty clutch, and Special Clutch Kit with 5 clutch friction disks.
Motorcycles with a frame number between Z50J-1300017 and 1805927 are equipped with an A-type spindle. So, be sure to replace thespindle with a B-type spindle.
B-Type Kickstarter Spindle Kit: 02-04-0011☆ Precautions in installing ☆

PY○ Unfasten all the stock washers, and instead, use thrust washers included in the Kit.
○ The inside of the left side crank case of 12V Monkey needs processing.
Gear ratio
Item No.
Kind
1st speed
2nd speed
3rd speed
4th speed
5th speed
Caution02-04-0200
Street2.357 (33/14)
1.764 (30/17)
1.400 (28/20)
1.136 (25/22)
0.958 (23/24)

02-04-0201
Super street
2.357 (33/14)
1.764 (30/17)
1.400 (28/20)
1.136 (25/22)
1.000 (24/24)

02-04-0202
S-touring
2.357 (33/14)
1.611 (29/18)
1.190 (25/21)
0.958 (23/24)
0.807 (21/26)

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

■ 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 toget 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 your motorcycle 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 ofstarting the engine of a racing motorcycle by moving 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 getdamaged owing to impact load 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.
◎ Please be informed that we shall be held harmless against any claim against us whatsoever arising out of use of the products inracing and the like.
◎ 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)2024.7.10

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Product content

3300-02-0299
3424

22161226
1835

23132417 16 16
16CO
1914201142030

20

1931

197

3 31

6 313030

95 30

12902-04-0200 （Street）
Product content
Quantity
Main shaft (14T)
1Counter shaft first gear (33T)
1Main shaft second gear (17T)
1Counter shaft second gear (30T)1Main shaft third/fourth gear (20T/22T)
1
Counter shaft third gear (28T)
1Counter shaft fourth gear (25T)1Main shaft fifth gear (24T)
1Counter shaft fifth gear (23T)
1Counter shaft
1

Item Number
00-02-0341
23421-165-T24
23431-051-T10
23441-051-T11
23451-051-T11
23461-051-T31
23481-051-T21
23491-051-T00
23501-051-T00
23221-165-T12

Number123456789
1002-04-0201 （Super Street）
Product content
Quantity
Main shaft (14T)
1Counter shaft first gear (33T)
1Main shaft second gear (17T)
1Counter shaft second gear (30T)1Main shaft third/fourth gear (20T/22T)
1
Counter shaft third gear (28T)
1Counter shaft fourth gear (25T)1Main shaft fifth gear (24T)
1Counter shaft fifth gear (24T)
1Counter shaft
1

Item Number
00-02-0341
23421-165-T24
23431-051-T10
23441-051-T11
23451-051-T11
23461-051-T31
23481-051-T21
23491-165-T12
23501-165-T11
23221-165-T12

Number1
234567891002-04-0202 （S-Touring）
Product content
Quantity
Main shaft (14T)
1Counter shaft first gear (33T)
1Main shaft second gear (18T)
1Counter shaft second gear (29T)1Main shaft third/fourth gear (21T/24T)
1
Counter shaft third gear (25T)
1Counter shaft fourth gear (23T)
1Main shaft fifth gear (26T)
1Counter shaft fifth gear (21T)
1Counter shaft
1

Item Number
00-02-0341
23421-165-T24
23431-181-T01
23441-181-T02
23451-181-T11
23461-181-T2123481-181-T22
23491-181-T11
23501-181-T11
23221-165-T12

2024.7.10

2500-02-0117

2728N

328Number12345678910

21303236

1502-04-0200,0201,0202

2PY10※ A component marked “N” shows a genuine part

Number11121314151617181920212223242526272829303132
33
3435
36

Common Parts
Product content
Thrust washer,13.5mm
Right gear shift fork
Center gear shift fork
Left gear shift fork
Gear shift drum
Shift drum 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
Gear shift drum side washer, 6x17x2.3
Hex bolt, 6x16Thrust washer, 14mm
External circlip, 17mm
Spline washer, 17mm
Thrust washer S, 17mm
Crankcace gasket (6V)
Crankcace gasket (12V)
Right crankcace cover gasket
Hex wrench, 5mmQuantity
111114113311121111153211
1
1

Item Number
00-02-0055
00-02-0014
00-02-0015
00-02-0016
00-02-0049 (5 pcs)
00-02-0018
24411-051-T01
00-02-0336
24263-165-T00
00-02-0118

00-02-0054
28211-165-T31
00-02-0013
00-02-0050
00-00-0032 (3 pcs)
00-02-0047
00-02-0005 (5 pcs)
00-02-0462 (5 pcs)
00-02-0024 (2 pcs)
00-01-1032
00-01-0096
00-01-0095※ 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.
※ Repair parts may differ slightly from the kit contents in terms ofshape, etc.
There is no problem to use it. Please be forewarned.

/5On processing
Caution 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 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 orchips into them.
※ Work with gloves on lest you should cut your hands withedges of the case.

Rasp the shaded area.

COAbout

18

Rasp here.
RR

Rasp here.

About 7mmmmR■ Mounting procedure※ Please refer to the genuine service manual if the detail is not mentioned method and the specified torque.

○ 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○ 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.

PY○ 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.

Meshing its friction spring with grooves in the left sidecrankcase,attach the starter spindle to the left side crankcase.
※ Apply engine oil to the starter pinion and starter spindle.

○ Degrease the mating surfaces of the right and left side crankcases.
And set a dowel pin and attach new gaskets. Put together theright and left side crankcases, and check that the they fit
together closely.
With the left side crankcase up, place the bolts, and tighten
first those placed in the middle, and then those placed outside
but diagonally and alternately.
Note: Be sure that you protect specified torque.
Bolt

Torque：10N・m（1.0kgf・m）
Dowel pin

Switch rotor

Neutral switch

Gasket2024.7.10

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

○ Put together the right and left side crankcases.
With the left side crankcase up, place the crankcase bolts on thecrankcase, and tighten them diagonally in a few steps to thespecified torque.

○ Install the gear shift drum side plate on the shift drum,
meshing the holes on the shift drum side plate with the stopper
plate setting pin.
Gear shift drumside plate

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

Torque：10N・m（1.0kgf・m）
6VCO○ Fit the shift gear drum stopper plate into the stopper platesetting pin,keeping the marking on the plate visible.
And then, apply thread lock cement to the thread of the dowelbolt, and tighten it to the specified torque.

○ Setting the round corner of the gear shift drum side washer to face
toward the shift drum, tighten a hex bolt to the specified torque.

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

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

Torque：16N・m（1.6kgf・m）
Apply the screw locking agent

Torque：12N・m（1.2kgf・m）

Laser marking

Gear shift drum side washer
Hex bolt○ Install the rubber plug.

Rubber plug

PY

○ Place the shift drum stopper spring in the shift drum stopperarm COMP., fit them into the gear shift drum stopper plate on thecase, and tighten the bolt to the specified torque.
※ Be careful not to get your fingers caught when fitting the spring
into the case.
Note: Be sure that you protect specified torque.

○ 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.

Retainer
External circlip

Torque：10N・m（1.0kgf・m）

Shift drum stopper arm COMP.

○ Fit four shift drum pins and two stopper plate setting pins into
the gear shift 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.
Shift drum pin

Stopper plate setting pin○ Turning the mainshaft with hands, turn the knock bolt on thegear shift drum stopper plate with a socket wrench, and check if
the gears can shift 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.
Then check every component for oil leak. If nothing is wrong, doa test run at slow speed in a safe place to check how thetransmission works.

Shift arm

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Transmission assembly drawing

Main shaft assembly
For a stock clutch
M5 gearM3/M4 gear
For a special clutch

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
Thrust washer S ,17mm

Spline washer, 17mm

◎ You can see this instruction manual on our website as PDF data .
If this document hard to read, please download it from our website.
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External circlip, 17mm