Instruction Manual for 4-Speed Close Transmission Kit
Contents
1. Instruction Manual for 4 Speed Close Transmission Kit item No 0D00 00 0000 Compatible models and frame Nos HONDA made 12V Monkey I zZ50J 2000001 Q AB27 1000001 0 12V Gorilla O0 z50J 2500001 AB27 1000001 Monkey BAJA Z50J 1700001 Monkey RT AB22 1007601 Monkey R 0 AB22 1011926 O Thank you for purchasing one of our TAKEGAWA made 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 O Features O The gear ratios of genuine 4 speed transmission on the Monkey are set to be very far apart from one another This is the kit to bring the gear ratios of 1st 2nd and 4th gears to be close to the 3rd gear ratio O We have managed to keep the prices reasonable by making use of the genuine 3 speed gear and countershaft O This kit can be used with our TAKEGAWA made Special Clutch and Heavy Duty Manual Clutch Kit 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 takes2. O When you notice something abnormal with your motorcycle while riding immediately stop riding and park your motorcycle in a safe place to check what has gone wrong Otherwise the malfunction could lead to accidents 0 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 are working O Check or carry out maintenance of your motorcycle correctly according to the procedures in the instruction manual or service manual Improper checking or maintenance could lead to accidents 0 If you find damaged parts when checking and 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 O 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 Kit includes Ne Part Name o Pr mainshae was t 2 mainshatt 2nd gear WITT T a Mensha ah gear We T 4 Countershatt Ist gear CI T 5 Countershatt and gear C2317 T 1 1 1 1 1 e Countershatt ah gear C247
3. T Kick starter gear 24T ze Mar 05 07 S O Installation Instructions Before starting the installation make sure to secure your bike on a maintenance stand on level ground for safety s sake O For installation of this kit please refer to a HONDA s service manual Please replace the genuine transmission gears of M1 2 4 C1 2 4 and kick starter gear with those provided in this kit X When assembling apply engine oil to cogs and rubbing surfaces of each gear O As the gear ratio of the transmission alters adjust the sprocket as the case may be O Incase a kick starter gear and left side crank case interfere with each other on bikes with Cut off here frame Nos of AB27 cut off the circled portion until the gear does not touch it Cover the bearings with a tape not to get any dirt dust or chips into it X Work with gloves on lest you should cut your hand with edges of the case O Transmission Assembly Drawing Parts in grey color show that the genuine ones are to be used Ly a M4 gear M227 pt Lp r Genuine spline washer Genuine circlip Ai eon sume E Sea Genuine circli ef A p Rs LAS ES 3 A N Genuine spline washer lt RA X esp MES gear 13T NO 6 f j Mainshaft Assembly Genuine thrust washer 14 mm X Chamfered edge to face inwardly A P c4 gear 24T LZ y f X 4 SOS Genuine thrust washer 13 5 mm amp s Genuine thru
4. e breakage of parts or injuries to you may take place 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 As some products and frames have sharp edges or protruding portions please work with your hands protected Otherwise you will suffer injuries 0 Before riding always check every hardware like screws for slack If you find slack ones screw them securely up to the specified torque Otherwise improper tightening may cause parts to come off 0 Make sure to change gears only after you have let throttle back to idle position Changing gears forcibly or at high engine revolutions will cause the gear and other parts 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 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 make are used the gear may get damaged owing to impact shock at the time of starting the engine with a kick starter WARNING The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the following warnings
5. place after the installation and use of the products Please note that this kit is designed for exclusive use in the above mentioned compatible models and frame numbers only and that it cannot be mounted on any other models Installation of this kit requires engine removal and reinstallation and crankcase splitting At some stages of the installation some special tools are required The work is only to replace the genuine gear with a provided one For the work please prepare and refer to a HONDA s service manual In installing the kit onto bikes with frame Nos of AB27 the case and kick starter gear may interfere with each other in some cases because of the individual difference in sizes of the left side crank case In this case the interfering portion needs to be cut off Do the disassembly and installation work correctly referring to the relative genuine service manual for the above mentioned compatible models Those who are technically unskilled or inexperienced are required not to do the work Improper installation because of insufficient skill or knowledge could lead to parts breakage Therefore we recommend those who are technically inexperienced or do not have enough tools to ask a technically reliable specialist shop for the work This kit contains gears only Gaskets packing O rings etc necessary for engine disassembly are not included which please purchase separately to meet the engine specifications Never reu
6. se worn down or severely damaged bolts packing or gaskets Make sure to replace them with new ones Genuine washers circlips and collars will be used However never reuse worn down or severely damaged ones Make sure to replace them with new ones Be sure never to use this gear in combination with other manufacturer s products like engine and clutch Otherwise 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 combination with other manufacturer s products You are requested not to contact us about the combination of our products with other manufacturers Please be informed that we shall be held harmless against any claim against us whatsoever arising out of use of the products in racing and the like Please be informed beforehand that the product specifications and the instruction manual are subject to change without prior notice due to product improvement This manual should be retained for future reference NX 2 Ze Mar 05 07 CAUTION The following show the envisioned possibility of injuries to human bodies and property damage as a result of disregarding the following cautions Always try to drive your motorcycle at legal speed abiding by the laws Work only when the engine and muffler are cool Otherwise you will get burned Do the installation with right tools Otherwis
7. st washer 17 2 mm Genuine C3 washer Genuine spline washer Genuine circlip Genuine spline washer black Genuine collar t 3 Countershaft Assembly List of Gear Ratio Stock transmission on 12V Monkey TAKEGAWA made close transmission S 3 272 36 11 2 615 34 13 SPECIAL PARTS WAKI YATA 3 5 16 Nishikiorihigashi Tondabayashi Osaka Japan anad E ea o U s3 Mar 05 07 TEL 81 721 25 1357 FAX 81 721 24 5059 URL http www takegawa co jp
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