SS5-Speed Transmission Kit for Dry
Contents
1. J Jul 06 11 O On processing AN CAUTION Always work with gloves on to protect your hands Otherwise you may suffer injuries Left side crankcase O Fold down the circled portion on the left side crankcase with a plier and rasp the circled portion with a file or a hand grinder Then wash the left side crankcase with water Xx Cover the bearings with a tape not to get any dirt dust or chips into them Xx Work with gloves on lest you should cut your hands with edges of the case About 7 mm O 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 or chips into them Xx Work with gloves on lest you should cut your hands with edges of the Rasp here case ee Y 5 J ul 06 11 Va O O Apply grease to the lips of the oil seal of the left side crankcase shift spindle Apply oil to the bearings of the right and left side crankcases And place the left side crankcase on the pedestal Apply oil to the 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 the grooves on the gear On installation Shift drum Counter shaft2. SS5 Speed Transmission Kit for Dry Type Clutch Instruction Manual O Thank you for purchasing one of our products Please strictly follow the Item No J instructions to install and use the kit Before installing the kit please be sure to check the kit contents If you have any questions about the kit please contact your local TAKEGAWA dealer Street Super street S Touring Super close 00 00 00 00 00 00 00 00 Please note Illustrations and photos may vary from actual hardware Fits O Monkey amp Gorilla Frame No Z50J 130001 7 AB27 1000001 1899999 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 y
3. 9 Counter shaft fourth gear 26 D1 23481165700 0 Man shaft fith gear 2 O S ML TCSTON CC TT Counter shaft fitth gear 24 E 2350E165100 i HE Common Parts M Part name Oty Repair part fem No In packs of 15 Gear shit dum I _ _ 16 Dowel pin IOS OO 17 Gear shit drum side plate 1 ovos 1 _ 18 Gear shit dum stopper pae 1 mro T _ 19 Gear sht fork gudepin 3 ovos 3 20 Gear shift fork guide pn cdp 3 226s 1 _ 21 Neural swich roor O O O O J a ooo CT CC 22 Smt drum stopper am COMP 1 o0200s S S 1 _ 23 Sht drum stopper sping 1 Soro O T _ 00 02 0054 uo o 0204 I 25 Kek starter pinion 251 1 meS S a _ 2 Knock bok em SSCS OT CP SC 27 Plain washer X3 1 oo o a 2 hebt ee CCS Ct ooa SSS S SC 30 hust washer 135mm 1 ooo S i 31 Extemal circlip Timm 5 00 02 0005 S 5 _ ee 32 Spline washer Imm 4 002 003 5 _ 33 Thrust washer 5 Timm 1 ovo iT a 34 Crankcace gasket OV 1 ooo SSS S It _ 35 Crankcace gasket 0M 1 ooo Od SC 36 Right crankcace cover gasket 1 ovoloms 1 _ 37 Hexwrench 5m o ooo ISSS S S S E E E E gt N x Please order repair parts with the Repair Part Item No Without the repair part item NO we may not be able to accept your orders Some parts are only available as a set In this case please order them with the set number
4. Main shaft O O Install into crankcase the main shaft counter shaft and shift drum all together as a unit x Do above installation with the transmission in neutral or at the position where the neutral switch and switch rotor mesh together Xx Never forget to install the thrust washer As the stock washer is not to be used remove it X Install the shaft with care so the lip of the countershaft oil seal may not turn up O URemove 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 of removal Meshing its friction spring with grooves in the left side crankcase attach the starter spindle to the left side crankcase x Apply engine oil to the starter pinion and starter spindle S O O 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 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 Specified torque 10 N m 1 0 kgf m Dowel pin Gasket O O Put together the right and left side crankcases With the left side crankcase up
5. S a 3 Man shaft fist gear 0 OOOO S I aa O a a Couer shat frst gear GIN I erea O a 73431 051 T01 6 Counter shaft second gear GON 1 2344 051 101 4 Q _ Main shaft third fourth gear 20 00 COE eae OS Oe 8 Counter shaft third gear 28T 23461 051 120 9 Counter shaft fourth gear 25T 23481 051 T10 10 Main shaft fifth gear 24 23491 165 TOL 11 Counter shaft fifth gear 24 23501 165 T00 02 04 0206 S Touring Mo Partname J Oly Repair part tem No In packs off 23212 165 T30 2 Comers T 22Sa S a 3 Man shaft fist gear aT OOOO S I aa o a a Couer shat frst gear GIN 1 TOBIN O 5 Man shat second gear 8 12er r 6 Counter shaft second gear 29 23441 181 TOL l A51 I81 TI0 7 Main shaft tirdfourth gear 211722 PT erierto E 8 Counter shaft third gear 25 9 Counter shaft fourth gear 23 1 23481 181 120 IT Counter shaft fifth gear 21 The transmission consists of N HOU UU O000 x A component marked N shows a genuine part 02 04 0207 Part name Super close ratio HI EA L E 2 E 2 Conese o OOOO OF 1 aaa O a 3 Man shatt stoer a O O a a OTC a Counter shat frst gear G3 1 era CC 5 Man shaft second gear 191 1 erno TC 6 Counter shaft second gear Q9 1 23441 165 T01 7 Main shaft third fournth gear 211 23 DES 23451165700 i 8 Counter shaft third gear 2 D1 461 165 100 i
6. place the crankcase bolts on the crankcase and tighten them diagonally in a few steps to the specified torque Specified torque 10 N m 1 0 kgf m O O 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 ee 4 Jul 06 11 O O Turn around the crankcase so the right side crankcase faces O0 O O Place the spring in the stopper arm fit them into the stopper plate upwards And install the kick starter spring and kick spring retainer to on the case and tighten the bolt to the specified torque the starter spindle And fit the spring end into the case with a click Specified torque 10 N m 1 0 kgf m And install the external circlip Xx Be careful not to get your fingers caught when fitting the spring x Be careful not to get your fingers caught when fitting the spring into into the case the case Stopper arm Fit the spring end into the case with a click 8 T Retainer O0 O O Turning the mainshaft with hands turn the knock bolt on the stopper plate with a socket wrench and check if the gears can shift smoothly Check that there is some free play in the mainshaft and countershaft in the direction of thrusting x Do not turn the shift drum forcibly Circlip O O Fit four dowel pins and two stopper plate setting pins into the shift drum and install the gear shift arm onto cr
7. 4 1000 24 24 0 807 21 26 The following show the envisioned possibility of injuries to human bodies or property damage as a result of disregarding the 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 O 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 O 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 O 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 motorcyc
8. 721 25 1357 FAX 81 721 24 5059 URL http www takegawa co jp A Jul 06 11
9. ankcase Xx Apply engine oil to the sliding surface of the shift spindle and gear shift arm Xx Apply grease to the lip of the oil seal for the left side crankcase shift spindle 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 do a test run at slow speed in a safe place to check how the transmission works Setting pin Dowel pin os O0 U Install the shift drum side plate on the shift drum meshing the holes on the shift drum side plate with the shift drum setting pin Side plate O O Uj 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 dowel bolt and tighten it to the specified torque Specified torque 16 N m 1 6 kgf m Apply the screw locking agent Laser marking z Jul 06 11 f f M1 gear Transmission assembly drawing Main shaft assembly M5 gear M3 M4 gear M2 gear OO _ Main shaft N C 17mm External circlip 17mm Spline washer 17mm Spline washer Counter shaft assembly C1 Gear C3 Gear C2 Gear C5 Gear C4 Gear 17mm External circlip 17mm External circlip 17mm Thrust washer S 17mm Spline washer SPECIAL PARTS WN4SeYWYA Co Ltd 3 5 16 Nishikiorihigashi Tondabayashi Osaka Japan TEL 81
10. le 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 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 this one after the installation and use of this product les manual should be retained for future reference wy e Jul 06 11 f 02 04 0204 Street MoJ Partname Oy Repair part tem No In packs of e E S TTS E 2 Counter sht T anea Td 3 Man shat stgr 0 OOOO S o O T a Counter shaft fist gear GIJ 1 2er i d 5 Man shat second gear O7 1 2er O 1 _ 6 Counter shaft second gear GON 1 _ 244 051 701 7 Main shaft thirdfourth gear 201 22 2s 1 __ e Counter shaft third gear 28 9 Counter shaft fourth gear 25 C0 Man shat h gear 241 OO O S oroo O a Cid LIT Counter shaft fifth gear 23 oro 1 HH Mo Prae J Oy Repair part tem No Jn packs of EELEE E CY E a E E 2 Comers T 22a
11. our proper work 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 Before riding check the all transmission gear and drive train that move and operate smooth and properly 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 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 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 O 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 is available 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 0 958 23 2
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