Instruction Manual for 4-Speed Close Gear Ratio Transmission Kit
Contents
1. Instruction Manual for 4 Speed Close Gear Ratio Transmission Kit for XR CRF50 tem NoQ 00 00 0000 Fits HONDA XR50R AE03 1000001 XR70R_ DEO2 13000011 CRF50F AE03 1400000 CRF70F DE02 1700001 O Thank you for purchasing one of our TAKEGAWA s products Please strictly follow the following instructions in installing and using the Kit O Before installing the Kit please be sure to check the Kit contents Should you have any questions about the Kit please contact your local motorcycle dealer Read all instructions first before starting the installation We do not take any responsibility for any accident or damage whatsoever arising from the use of the Kit not in conformity with the instructions in this Instruction Manual We shall be held free from any responsibility or compensation whatsoever for any glitch in the parts other than ours if the glitch takes place after the installation and use of this Kit Please note that this Kit is designed for exclusive use in the above mentioned fitting models with the specified frame numbers only and that it cannot be mounted on any other models Installation of this Kit requires some work from removal and mounting of the engine to splitting of the crankcase At some stages of the installation some special tools are required Do the installation work correctly referring to the relative genuine service manual for the above mentioned fitting2. s3 Aug 29 07 XK Part Name Qty Repair Part Item No A Kick starter pinion 8211 GEF T0O ork gear shift 24018 0015 n gearshift fork guide hift fork guide pin clip rum gearshift 7 N as E W n N as Pr N 24018 0021 eutral switch rotor K Roller 3 x 8 5 Please reuse genuine parts for those unnumbered parts ate gearshift drum side ate gearshift drum stopper pring shiftdrum stopper EZA in gearshift drum in packs of 1 Aug 29 07 Mainshaft COMP M3 gear 20T M4 gear 22T M2 gear 17T 020 04 0015 23471 GB7 T00 23431 GB7 T00 m Mainshaft 13T B ital 23211 GB7 T00 TH Genuine thrust washer 14 mm as External circlip 17 mm Spline washer 17 mm Ste Countershaft COMP C1 gear 34T c2 31T 23421 GB7 T00 gear 11 23441 GB7 T00 C4 gear 24T C3 gear 27T 23481 GB7 T00 020 04 0016 S Countershaft J 020 04 0018 rl DN o Ly Cy Collar countershaft low gear 020 04 0017 Genuine thrust washer 13 5 mm Thrust washer 17 2 mm 020 04 0012 Washer B spline 17 mm External circlip 17 mm
3. 020 04 0014 Spline washer 17 mm Repar Tem No Spline washer 17 mm 241 38 ae eee circlip 17 mm 4 241 39 fF 5 5 Aug 29 07 SPECIAL PARTS TENKQSCYNWA Co Ltd 3 5 16 Nishikiorihigashi Tondabayashi Osaka Japan TEL 81 721 25 1357 FAX 81 721 24 5059 URL http www takegawa co jp JY
4. are working O Carry out inspection and maintenance of your motorcycle correctly according to the instructions and guidelines in the instruction and service manuals Improper inspection or maintenance could lead to accidents 0 If you find damaged parts when inspecting or performing maintenance of your motorcycle 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 accidents 0 Keep plastic bags for packing the products out of children s reach or discard them If children get them on there will be a danger of their suffocating 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 O Features O This is a 4 speed transmission kit designed with a gear ratio for sports driving as compared with a genuine 3 speed transmission O This Kit can be used with our TAKEGAWA s Heavy Duty Centrifugal Clutch Special Clutch or Heavy Duty Manual Clutch Kit Gear Ratio List Sib arsiission on CRFSOF TAREGAWAS dose rato Tarsmission 3rd speed a speed e S 20220 Kit includes wp em fo 1 Mainshatt sery 7 2 Counteshatt asserby 1 Gearshift drum assembly 1 hift drum side plate 7 Shift drum cam Eo 8 Shift drum stopper spring 1 po iRofes
5. every gear and every sliding surface Note To the countershaft install only a 13 5mm genuine thrust washer And a 30x1 7 washer B thrust is not to be used with this kit 13 5mm i Genuine thrust washer A 14 0 mm c2 7 7 SS Ka 0 D Attach the kick starter spindle to the crankcase meshing its friction spring with a groove in the crankcase T 0 O Clean the mating surfaces on the crankcases and attach a knock pin and a new gasket to the crankcase Note A gasket is not included in this Kit Please prepare one separately which meets the engine specification O O Referring to the genuine service manual install the right side crankcase being careful not to let the gasket get out of place O Installation Instructions O Support the motorcycle upright on a maintenance stand on level and safe ground for safety s sake O As what you do is only to replace the genuine parts with those of the Kit basically follow the work and procedures in the genuine service manual This Instruction Manual only outlines the work different from the work mentioned in the genuine service manual S 0 D Attach a genuine gearshift arm COMP and spindle spring to the right side crankcase and to the gearshift drum attach three gearshift drum pins of No 5 and two rollers of No 9 0 OFirst attach a shift drum side plate of No 6 and then a shift drum cam of No 7 Reuse a genuine cam plate bolt and tighten it to the specified to
6. S For repair parts Nos please refer to the list on the last page of this Instruction Manual EA Shift drum pins 6s Ew 3 1 1 1 Zoe Aug 29 07 la Please prepare a genuine service manual needed for the installation 0 O Referring to the genuine service manual split the crankcase 0 O Change the kick starter pinion of the kick starter spindle with the one No 3 included in the Kit OO After changing the kick starter pinion temporarily install it to the left side crankcase and rotate it to check whether or not the kick starter pinion and left side crankcase interfere with each other If the two interfere with each other scrape the crankcase with a hand grinder until there is no more interference at the circled portion Cover the bearing with a tape not to get any dirt dust or chips into it Work with gloves on so you do not get your hands cut with the edge of the case or the like X After scraping the case wash it not to leave the cuttings in the case 0 0 Place the left side crankcase on the maintenance stand or the like and fabricate the mainshaft assembly No 1 countershaft assembly No 2 and gearshift drum assembly No 4 And then install the fabricated unit into the case Place a 14mm genuine thrust washer between the mainshaft and the left side crankcase and a 13 5mm genuine thrust washer between C4 gear and right side crankcase And apply engine oil to the teeth of
7. models Besides this Instruction Manual as well as a service manual is prepared for those who have acquired basic skill and knowledge Therefore those who are not skilled or do not have sufficient knowledge may not be able to install the Kit correctly leading to parts breakage Therefore we recommend those who are technically inexperienced or do not have sufficient tools to ask a technically reliable specialist shop for the work This instruction manual covers the installation work only after the stages of the engine removal from the body and crankcase splitting Do the removal work correctly before these stages referring to the relative HONDA s genuine service manual for the above mentioned fitting models The crankcase and kick starter gear may interfere with each other in some cases because of the difference in sizes of the left side crank case In this case the interfering portion needs to be cut off This Kit does not contain gaskets packings O rings etc necessary for engine disassembly which please purchase separately to meet the engine specifications Never reuse worn down or severely damaged bolts packings or gaskets Make sure to replace them with new ones Be sure to never use this Kit in combination with other manufacturers products like engine and clutch There is a possibility that parts may be damaged And we shall be held harmless against any breakage or damage of any part caused by the use of this Kit in combi
8. nation with other manufacturers products You are requested not to contact us about the combination of our products with other manufacturers The drive sprocket spline on the countershaft being different from the genuine one you are required to procure a drive sprocket for the Monkey additionally As the gear ratio of the transmission changes adjust the number of sprocket teeth as the case may be A genuine centrifugal clutch and our TAKEGAWA s heavy duty clutch can be used as they are However with these clutches mechanically it is rather difficult to shift to neutral Therefore we advise you to use this Kit with our TAKEGAWA s Manual Clutch Kit or Special Kit The following show the envisioned possibility of injuries to human bodies and property damage as a result of disregarding the CAUTION following cautions O Work only when the engine and muffler are cool Otherwise you will get burned 0 Do the installation with right tools Otherwise breakage of parts or injuries to you may take place 0 Always use a torque wrench to screw bolts and nuts tight and securely to the specified torque Otherwise these parts may get damaged or fall off resulting in accidents O As some products and frames have sharp edges or protruding portions please work with your hands protected Otherwise you will suffer injuries O Before riding always check every hardware like screws for slack If you find slack ones screw them
9. rque Torque 17 NO m 1 7 kgf m 0 O OChange a return spring in the shift drum stopper arm with a supplied shift drum stopper spring of No 8 and install the stopper arm And tighten the bolt to the specified torque Torque 13 NO m 1 3 kgf0 m O 0 D Referring to the genuine service manual reinstall back the engine and mount it on the motorcycle In case this Kit is to be installed onto a motorcycle with a centrifugal clutch as it is please also refer to the step below In the case of installing this Kit onto a motorcycle with a centrifugal clutch as it is 0 0 0 Please separately prepare a drive sprocket for the MONKEY for installation As the gear ratio of the transmission changes adjust the number of sprocket teeth as the case may be In the case of installing this Kit onto a motorcycle with a centrifugal clutch as it is Although it is possible to install this Kit onto a motorcycle with a centrifugal clutch in some cases it will be mechanically hard to shift to neutral This is because when shifting to neutral the shift pedal slides only slightly and thus the clutch cannot be disengaged In order to make the gearshift to neutral easier even if only slightly adjust the clutch after the installation of this Kit so you will get as little free play as possible To get the fundamental solution of this problem it is advisable that you use this Kit with our TAKEGAWA s Manual Clutch Kit or Special Clutch Kit J
10. securely up to the specified torque Otherwise improper tightening may cause parts to come off O The installation of this Kit will change the gear change pattern to the return system of 1 down 3 up Change gear only when you have let throttle back to idle position Changing gears forcibly or at high engine revolutions will cause the gear and other hardware to get damaged or worn out O 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 0 Please never use this Kit in combination with other manufacturers ignition system parts because it is likely that if ignition system parts of other manufacturers are used the gear may get damaged owing to impact shock felt at the time of starting the engine with a kick starter a Is Aug 29 07 WARNING The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the following warnings O When you notice something unusual with your motorcycle while riding immediately stop riding and park your motorcycle in a safe place Otherwise the unusuality could lead to accidents Before doing work make sure your motorcycle is secure on level ground for safety s sake Otherwise your motorcycle could overturn and injure you while you
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