Hyper S-Stage KIT (88cc) Instruction ManualThis Kit is to bore up the engine displacement to 88 cc, using a standard cylinder head.
The ceramic-coated cylinder is used.
Oil lines in this cylinder with oil outlets lead the oil to the outlets.
Also, set M5 threaded hole in the oil plug bolt, it can be installed in our M5 temperature sensor.

CO

Item No. ０１―０５―５０１０ (With oil outlets)
Monkey (FI) : AB27-1900001〜

・Thank you for purchasing one of our products. Please strictly follow the 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.

NoticePlease note: Illustrations and photos may vary from actual hardware.

About fuel to use

This S-Stage Kit is so designed to achieve a higher compression ratio than stock engines. Therefore, high-octane gasoline should always be used. In caseregular gasoline is used, you cannot get the performance of this Kit. Moreover, it is possible that the piston will be damaged, leading to a serious failureof a motorcycle. Before installing this kit, make sure that no regular gasoline remains in the fuel tank. In case regular gasoline is remaining in the fuel tank,do replace it with high-octane gasoline.

About the spark plug

Be sure to replace a spark plug with a CR8HSA (NGK) or U24FSR-U(DENSO).

About quick starting and sudden acceleration

PY

Please note that idling, sudden acceleration, and sudden engine braking will put a heavy load on the engine, and that it may result in crank shaft and engine
damages in the worst case.

Instructions for use of FI controller

If you start the engine only with the S-Stage Kit installed, the major malfunction of the engine is likely to take place. So, be sure to install the FI controller.

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.
◎ Please drive safely and follow the local traffic law.
◎ We shall be held free from any kind of warranty whatsoever of products other than this product if any defect takes place on the other products than this one after the installation
and use of this product.
◎ If you make modifications to any product of the Kit, we shall be held free from any guarantee of the product.
◎ We do not have any information or service data on the combination of our products and other manufacturer’s products.
◎ Please note that this Kit is designed for exclusive use in the above-mentioned fitting models and frame numbers only and that it cannot be mounted on any other models.
◎For installation, please prepare tools and work with reference to the installation procedures with enough care. Besides, this instruction manual, as well as a HONDA’s genuine parts
service manual, is prepared for persons who have acquired basic skills and knowledge. We recommend those who are technically inexperienced or without enough tools to ask atechnically-reliable specialist shop for the installation work.
◎ Bolts, nuts, dowel pins and seals will be reused. However, be sure not to use the worn-down or severely-damaged ones, which please do replace with new ones.
◎ This Instruction Manual is prepared mainly for installation on the Monkey (FI).
◎Fuel must always be supreme unleaded high-octane gasoline.
◎ Since the crankcase emission control system is easy to plug the filter with dust, check to see the plugging every about 1000km trips.
If plugged, clean the filter or use a new one.
NOTE: Continuing use of it, it may cause the lack of performance.

CAUTION The following show the envisioned possibility of injuries to human bodies and property damage as a result of disregarding the following cautions.
・Please drive safely and follow the local traffic law.
・Work only when the engine and exhaust system are cool to avoid burns.
・Prepare appropriate tools and work properly to avoid the breakage of parts or injuries.
・Always use a torque wrench to tighten bolts and nuts securely to the specified torque to avoid these parts getting damaged or loose.
・As some products and frames have sharp edges or protruding portions, work with your hands protected to avoid injuries.
・Before riding, always check such parts as screws for loose. If you find loose ones, screw them securely up to the specified torque to avoid parts coming off.
・Always use new gaskets and seals. About the reused parts, please check carefully for wear or damage and be sure to replace them with new ones if necessary.

WARNING The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the following warnings.
・Always start the engine in a well-ventilated place, and do not turn on the engine in an airtight place. (Otherwise, you will suffer from carbon monoxide poisoning.)
・When you notice something abnormal with your motorcycle, stop riding immediately and park your motorcycle in a safe place to avoid an accident.
・Before working, place the motorcycle on level ground to stabilize its position for safety to avoid the motorcycle overturning.
・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.)
・If you find damaged parts when inspecting or performing maintenance of your motorcycle, do not use these parts, and replace them with new ones.
(The continued use of these damaged parts could lead to accidents.)
・As gasoline is highly flammable, never place it close to fire. Make sure that nothing flammable is near the gasoline. Since vaporized accumulation of gasoline is at high riskof explosion, work in a well-ventilated place. (Otherwise it may cause a fire.)◎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.

‑1‑

Oct./21/ 10

rev.Nov./19/ 15

Lesson◇ Bolts and nuts will get loose when turned counterclockwise, and tighten when turned clockwise(some exceptions).
◇ At the beginning, hand tighten a screw without using a tool until it stops. If it stops turning after giving it one or two turns, the screw may be fixed improperly.
◇ To loosen a screw means turning a tightened screw three or four times to the counterclockwise, and to remove it means turning it until it comes off.
◇To tighten a screw means to screw it up to keep it from getting loose. The numeric value as a guide at which a screw will not break or get loose when tightened is the so-called“torque.” If you do not have a torque wrench, please try to tighten a screw as tight as possible to the point where the screw will not break or get loose, though we can not take any
responsibility for the breakage. In case you do not use a torque wrench, you need to judge, only by intuition or using experience, the degree of tightening power at which the bolt
will break or get loose.
◇ Improper use of tools will result in breakage of a top of a bolt or screw.

CO◇ Kit includes:

０１―０２―０１２２

０１―１３―８００９０３―０１―１１０６

５

１

３

２

No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

１２

９

１９

１０
１８

４

１１

１７

６７

８

１４

１６

１５

１３

Part Name
PistonPiston ring
Piston pin
Piston pin circlip
Cylinder, 52 mm
Oil plug bolt
Oil plug bolt with M5 holes
Sealing washer, 10 mm
Cylinder head gasket
Cylinder gasket
Exhaust pipe gasket
Camshaft
Flange bolt, 6x25
Spark plug
Driven sprocket (with plate) 16T
FI Controller (for S-Stage)
Air filter COMP.
Clamp band
Flange U nut, M6
Mark set

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Qty
1
1
1
2
1
1
1
2
1
1
1
1
1
１
１
１
1
1
1
1

Repair Part Item No.
13101-GBJ-T01
13011-181-T10
00-01-0091 (with two circlips)
00-01-0003
12101-GBJ-T02
00-07-0072 (with Sealing washer)
00-07-0090 (with Sealing washer)
00-07-0010

２０

In packs of
1
1
1
6
1
1
1
10

01-13-8009

1set

00-01-0064
01-08-0332
00-00-0115
NGK-CR8HSA
02-05-051
03-05-0019

2
1
5
１
１
１

00-00-0014
00-00-0091

1
6∴ Please order repair parts with the Repair Part Item No. Without the repair part item No., we may not be able to provide the correct parts.
Some parts are only available as a set. Please order them with the set number.

◇ Tools to use for the installation

1
2
3
4
5
6
7
8
9
10

Torque wrench
Plastic hammer
Cutter knife
Open-end wrench 8-10
Open-end wrench 12-14
Open-end wrench 14-17
Offset box wrench 8-10
Offset box wrench 12-14
Offset box wrench 14-17
Spark plug wrench handle (in-vehicle tool）

‑2‑

11
12
13
14
15
16
17
18
19
20

Spark plug wrench (in-vehicle tool)
Needle-nose plier
Thickness gauge
Fine-shaft flat tip screwdriver
Extension (medium)
Extension (small)
Socket 14 mm
Socket 12 mm
Socket 10 mm
Ratchet wrench
Oct./21/ 10

rev.Nov./19/ 15

Head cover bolt

‑3‑

Cylinder head cover

Flange bolt, 6x32

O2 sensor stay

Cylinder headgasket※1 Dowel pin, 8x14

Bolt, 6x14

Valve rocker arm
Cam shaft

Flange bolt, 6x14

Knock bolt 5mm

Sealing washer

O2 sensor stay

Piston ring set

Coupler

Cylinder

Guide roller pin

Piston pin clip

Piston pin

Bolt, 6x14

Washer, 8mm

Cylinder gasket

Piston※1 Dowel pin, 8x14

※１ NOTE: There are several kinds of length for dowel
pins. Please make sure of the size before installing.
※２ These hardware is not included in the kit orwill not be used for the installation of this kit.
※３ Be sure to use CR8HSA (NGK) or
U24FSR-U (DENSO).

Side bolt, 6x25

Thermostat oil
sensor guard

Oil temperature※2 Side bolt,
sensor6x25

Cam chainguide roller

Flange bolt, 6x14

Cam stopper plate

O-ringCam sprocket※1 Dowel pin, 8x12

Rocker arm shaft※3 Spark plug
Cylinder head plate

Cylinder head

Insulator

O-ringPY

Flange nut, 7mm

Head cover gasket

Inlet pipe

Part names

CO

Oct./21/ 10

５．Remove a spark plug.

Removal of standard
hardware
１．Remove the inlet pipe.

CO◇Holding the flywheel, remove two hex bolts on the◇Remove two hex bolts, which are holding the exhaust
cam sprocket by turning them counterclockwise.
system, by turning them counterclockwise.
◇Remove a plug cap from the plug by pulling it out.
Tool:
Tool:
Be sure to hold the cap in pulling it out.
Offset box wrench, 8mm
Ratchet wrench
Socket, 14mm & Extension (medium)◇With an in-vehicle tool of a plug wrench, turn the plug
◇Remove two bolts by turning them counterclockwise
Extension (medium)(used for holding the flywheel)counterclockwise to remove it.
which hold a cylinder head and inlet pipe.
Socket, 12mm & Extension (small)
After removing as above, remove the insulator as
well.
６．Remove a cylinder-head cover.
Tool:
Offset box wrench, 8mm

Insulator

２．Remove the O2 sensor bracket.

◇Remove the exhaust system from the vehicle by pulling
it outwards. Take care NOT to lose ring-shaped
exhaust system gaskets.
◇Unfasten a hex bolt on the cylinder head cover toremove the cover.
Tool:
４．Remove the air cleaner box.
Socket, 10mm
◇Unfasten the screw and remove the side cover.

◇Gently pry the cam sprocket loose to remove from thecamshaft with a small-sized slotted screwdriver.
◇Remove the cam chain from the cam sprocket, andtake out the cam sprocket.
◇Remove a dowel pin fixed in the center of thecamshaft.

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９．Remove cylinder-head side bolts.

Side cover ７．Remove a crankcase left-side cover.

Ｂ

GrommetProtruding portions

Screw

Ａ
◇Remove the mounting bolt of air cleaner box and loose◇Remove the cylinder-head side bolts holding thethe band screw. Then remove the connecting tube of air
cylinder head and cylinder by turning themcleaner box.
◇Turn both A and B counterclockwise to remove them.
counterclockwise.
Tool:
Tool:
Band screw
Flat tip screwdriver
Mounting bolt
Offset box wrench, 10mm
８．Remove a cam sprocket.

◇Remove an O 2-sensor bracket on the cylinder.
Tool:
Offset box wrench, 10mm

３．Remove the exhaust system.

Timing markConnecting tube
O2 sensor◇Pull out the air cleaner box to the left (of the driving
direction) of the vehicle, and disconnect the breather
hose of crankcase. (The genuine hose will be reused.)

Breather hoseof crankcase

Coupler◇Remove the coupler of the O 2 sensor.

Air cleaner box
Notch

Guide roller bolt

◇Remove two nuts on the exhaust pipe by turning themcounterclockwise.
Tool:
Offset box wrench, 10mm

T markSide bolt◇Set the flywheel and cam sprocket so the “T” and “O”
marks on them respectively face forward. And set thetiming marks to be in contact with the cylinder headsurfaces. And turn the flywheel counterclockwise so itmeshes with each notch.

‑4‑◇Loosen the guide roller bolt on the cylinder and theside bolt between cylinder and crankcase byturning them counterclockwise.
Tool:
Open-end wrench, 8mm & or Offset box wrench, 10mm

Oct./21/ 10

１０．Remove the plate.

Installation of S-Stage Kit:
１．Assemble and install a piston.

Oil-temperature
sensorCO

Coupler◇Remove the piston.

Cylinder head plate◇Remove the oil temperature sensor by removing its
coupler.
◇Turn four nuts, which are holding the cylinder head,Tool:diagonally and counterclockwise in a few steps toOpen-end wrench, 17mm
remove them.
◇Remove the cylinder head plate.

１４．Remove a cylinder gasket,
rubber seal and dowel pin.

◇Fix a supplied piston pin circlip securely to the grooves
for circlip on one side of the piston. Be sure to set acirclip so its end gap is not on the notch.

Cylinder gasket

Tool:

Exhaust mark

Offset box wrench, 10mm

１１．Remove the cylinder head.

◇Pull out the cylinder. (If it is hard to pull it out, tap thecylinder with a plastic hammer.)◇If the gasket does not remove smoothly, please use thescraper or cutter but NOT scratch the crankcase.
Also remove the excess of the gasket if necessary.

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Keep off any dirt or unwanted parts.

damage the piston with the screwdriver.
◇Fix the piston pin circlip first on the left side.

How to rectify◇While removing the cylinder, the cam chain guide roller
will come out, which please remove.

１３．Remove the piston.

without bumps.

◇Plug the cylinder hole in the crankcase with a waste
cloth so as never to let the dirt, dust or hardware into thecylinder hole and cam chain.

◇Let out the air of the tire. Pushing the tire as shownin the photo, pull out the cylinder head forward out of
the cylinder. (If it does not move smoothly, tap thehead with a plastic hammer.)

２．Rasp the higher mating surface ofthe crankcases till it becomes levelwith the lower one.
３．After rasping the surface,remove the waste cloth with care
not to let the shavings get into the
crankcase.
４．After removing the waste cloth,

stuff up the crankcase opening
with a clean waste cloth.
After the installation of the Kit, idle
away the engine for a few
minutes, and then, immediately
replace the engine oil with new
one without delay. And there isnothing more to do.

◇Take care NOT to lose two dowel pins as they arereused.

１２．Remove the cylinder.

Tool:
Fine-shaft flat tip screwdriver◇Apply engine oil to the piston-ring grooves, and fix

As shown in the figure below, at thispoint rectify the crankcase to be even

１．Plug the entire hole in the
crankcase securely with a waste
cloth so the cutting chips andshavings won’t get into the
crankcase.

◇Remove a front fender.

◇You can rather easily install the piston pin circlip bypressing it with a screwdriver, but taking care not to

Piston pin circlip◇Remove one of the two piston pin circlips. You canremove it by prying it open with a screwdriver tip
being placed on the notch.
Tool:
Fine-shaft flat tip screwdriver

piston rings in the order of an oil ring expander, lower
oil ring side rail, upper oil ring side rail, second ring,and top ring.

◇Arrange the positions of piston ring-end gaps sothey do not align with each other.

トップリングTop ring

120°

120°

120°

Second ring
セカンドリング

エキスパンダー
ExpanderサイドレールSide rails

60°

60°

On the top surface of the top
ring is stamped “R”, and “RN”
on the top surface of thesecond-ring.

Right side crankcase Left side crankcase

Top ring
トップリングセカンドリング
Second ring

GasketサイドレールSide rails

ピストン
PistonExpander◇Remove the loosened guide roller bolt and cylinder

Pay attention to the cross section
as well !!

side bolt by turning them counterclockwise.
◇Remove the piston pin in the direction where the piston
circlip is not attached. You can easily remove the piston
pin by pressing it with a flat tip screwdriver from thedirection where a piston pin circlip is attached.

‑5‑

After
rectification

Oct./21/ 10

◇Apply engine oil to the ring grooves.

◇Put the expander.

CO◇Install the supplied flange bolt, M6 x 25.
(Fasten it only finger tight for now at this point.)◇Apply engine oil onto the inside of the supplied cylinder◇Pass the piston pin into con’rod and piston.

and spread the oil evenly with fingers.

◇Fix securely the supplied piston pin circlip to the circlip
groove.

◇Put the lower side rail.

◇Put the upper side rail.

Oil-temperature
sensor
Coupler◇Insert the cylinder.

◇Install the piston pin circlip to the piston, with a needlenose plier when necessary, being careful not todamage the piston.

◇Install the oil-temperature sensor, which pleasetighten to the specified torque.
After the installation, fix a coupler.
Tightenning:14.5N･m(1.5kgf･m)
Tool:
Open-end wrench, 17mm

３．Change of camshaft.

PY

Install the circlip so its end-gap is not on the notch.
Do the work carefully as, in some cases, the circlip

comes off flying while you are pressing it inside.
So, wear protective eyeglasses lest it should get into

your eyes.

◇When you are through with the work, remove the waste
cloth which was plugged into the hole.

◇Put the second ring.

２．Installation of cylinder.

◇Fit the cylinder by pressing it with a finger bit by bit,taking care so the piston ring-end gaps do not get outof position.

◇Degrease with thinner the cylinder gasket surfaces onboth cylinder and crankcase sides.

◇Put the top ring.

◇Once the ring has been placed inside the cylinder,route the cam chain through the cylinder, and fix thecylinder into the crankcase.

◇Apply engine oil to the piston.

◇ Loosen a tappet adjusting nut of the rocker arm
assembled into the cylinder head. And by turning thetappet adjusting screw counterclockwise, detach thetappet adjusting nut together with the tappet
adjusting screw at the same time.
Tool:
Offset box wrench, 9mm

Stopper plate◇Remove a stopper plate.
◇Pulling the cam chain, fix the guide roller.
◇Install the cylinder gasket.

◇Press in the guide roller so the center of the guideroller and the guide-roller bolt hole on the cylinder
just mesh together.

◇Apply engine oil to the piston pin on the con’rod.

Exhaust mark◇Check if the dowel pin is present.
◇Fix the piston so the arrow on the piston head faces◇Install the guide roller bolt.

downward, or to the exhaust side.

(Fasten it only finger tight for now at this point.)‑6‑◇Removing a stock camshaft, and install the supplied
camshaft in the reverse order from removal.
Apply clean engine oil to the camshaft and its
bearings. Even if you cannot easily fix the camshaft,
fix it manually without striking it with a hammer.
◇Attach the dowel pins, originally attached to the stock
camshaft, to the supplied camshaft.
Stopper plate bolt
12N・m (1.2 kgf・m)
Oct./21/ 10

Guide roller bolt

４．Installation of cylinder head.
◇With thinner, degrease the cylinder head surface
and upper surface of the cylinder.

CO◇Holding the flywheel, tighten up two cam sprocket bolts.
Tightening torque: 9 N･m (0.9 kgf･m)
Tool:
Socket, 8mm
Socket, 14mm & Extension (medium)Side bolts

Tightening torque:
10 N･m (1.0 kgf･m) for a guide roller bolt

◇While tightening a rocker arm’s tappet adjustingscrew, tighten the tappet adjusting nut to the extent
that you can pull out a thickness gauge, placed
between the tappet adjusting screw and the valve stem
end, feeling only a little resistance.
IN: 0.10 mm

10 N･m (1.0 kgf･m) for lower and upper sidebolts

EX: 0.12 mm

Tool:

Tool:
Needle-nose plier

Socket, 8mm,10mm

Offset box wrench, 9mm
Thickness gauge

５．Installation of cam sprocket.

Fit together the crankcases with a 14mm box wrench
and medium-sized long joint.
◇After adjusting the tappet, give the flywheel two turns

Notchcounterclockwise by hand, and then, align the “T”
with “O” marks.
◇Install the just-removed bolt next to the change pedal◇Check if there is any change in the tappet clearance.
shaft, and tighten it up.
Tightening torque: 10 N･m (1.0 kgf･m)
If the clearance has not changed, there is no need toTool:readjust it. However, in case there is a change,
Socket, 10mm & Extension (medium)readjust the clearance. Repeat this readjustment until
you get a right tappet clearance.

◇Fix dowel pins to the cylinder, and then headgaskets.

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T mark

６．Valve timing adjustment andtappet clearance adjustment.

Oil plug bolt with M5 holes
Sealing washer◇Align the T mark on the flywheel with the notch on the
crankcase, and set the piston at the compression top
dead center position.

◇Set the shaft so the cam top faces the piston when the

Timing markcam sprocket bolt hole is turned toward the notch on thecylinder head. This arrangement places the cam shaft◇Install the cylinder head, fitting the cam chain andstud bolts in place.

at TDC (Top Dead Center) on the compression stroke.

Oil plug bolt
◇The boss two places of the supplied cylinder, attach

Notch

the oil plug bolt / sealing washer.
Oil plug bolt with M5 holes, mounted so as to be on

the upper side when the engine mounting.
※If you are installing the oil cooler kit, that you follow

T markCylinder head plate◇Attach the cylinder head plate and tighten the headnuts evenly.
Tightening torque:14 N･m (1.4 kgf･m)
Tool:
Socket, 10mm

Oil will flow out a little after the bolt is tightened.
Wipe off the oil.

the instruction manual of the kit.
Tightening torque:12 N･m (1.2 kgf･m)◇Give the crankshaft two clockwise turns. And check that
all the alignment marks are meshing with one anotherwith the T mark on the flywheel, the notch on the
crankcase and the timing sprocket mark facing the front.

◇Unscrew a hex bolt on the side of the change-pedal

shaft. (As the cam chain tensioner slackens, you willfind it easier to install the cam chain.)

Valve clearance(Intake side)

O2 Sensor
Coupler◇Attach an O2 sensor coupler.

Timing mark７．Installation of cylinder head cover.

◇Attach a head side bolt. Fully tighten the guide roller
bolts and the cylinder side bolts which were tight- ◇Set the cam sprocket so its “O” mark faces the front.
ened temporarily.
And mesh the timing marks with mating surfaces of theTool:cylinder head cover. Aligning the notches together,
Open-end wrench, 8mm

Valve clearance(Exhaust side)
Adjusting screw

place the cam chain on the camshaft.

Offset box wrench, 10mm

Thickness gauge
Valve stem

◇Attach a cylinder-head cover and gasket.
Tightening torque:12 N･m (1.2 kgf･m)
Tool:
Socket, 10mm

‑7‑

Oct./21/ 10

rev.Nov./19/ 15

８．Installation of spark plug.

１０．Installation of inlet pipe.

CO

Masterlink

Link plate◇Put the clamp band on the rubber of air filter and installon the genuine throttle body.

◇Install the plug with either an in-vehicle tool or spark◇Detach a link plate and master link to remove thedrive chain.
※Be sure to stop the engine while you are working.

plug wrench.
Tightening torque: 16 N･m (1.6 kgf･m)

The logo of TAKEGAWA is to be on the level.
◇Put the genuine crank case breather hose into the outlet

Tool:
Spark plug wrenchof the air filter. Cut out the hose length as required.
◇Tighten the clamp band of the air filter.
◇Restore the side cover and the exhaust heat protector.

◇Attach a plug cap to the plug.

１２．Installation of a hole cap.

９．Installation of stock muffler.

◇Install an O 2-sensor bracket.
Tightening torque: 10 N･m (1.0 kgf･m)
Tool:
Socket, 10mm

Insulator◇Install an exhaust system.

◇Squeeze the muffler gaskets into the space between

cylinder head and muffler. And install the muffler unit
into the pivot shaft. Tighten the nut to hold the muffler
unit. (Finger-tighten the nut for the moment.)◇Unfasten two bolts.
Tool:
Socket 10 mm

Ｂ

Extension, (short)

PY
Ａ◇Fix and tighten both A and B.
Tightening torque:A

1.5 N･m (0.15 kgf･m)

B 3 N･m (0.3 kgf･m)
Tool:
Flat tip screwdriver◇Remove a plate◇Attach a change pedal.
Tightening torque:10 N･m (1.0 kgf･m)
Tool:

Socket, 10mm
◇Check bolts for slack which have just been installed up
to now on the engine, muffler, inlet pipe and other piecesof hardware.

◇Attach two bolts which hold the cylinder head and inlet◇Tighten two nuts on the exhaust pipe loosely for now.
pipe.
Tool:
Tightening torque: 10 N･m (1.0 kgf･m)
Open-end wrench, 10mm
Tool:
Socket, 8mm

１３．Installation of drive sprocket.
(on the engine side)◇Pull out a stock sprocket from the shaft to detach achain.

１１．Installation of air filter◇Make sure the motorcycle is secure on the stand like a
racing stand, and remove the step bar, and (L)◇Fit a supplied sprocket into the shaft.

crankcase cover.
◇Remove the drive sprocket cover, chain cover and steps.

◇Tighten the nuts to hold the flange and vehicle.
Tightening torque:
10 N･m (1.0 kgf･m) for flange
20 N･m (2.0 kgf･m) for the vehicle
Tool:
Socket, 12mm

Clip
◇Install the flange nut (M6) in the kit on the back of the◇Detach a clip from the drive chain.
bracket which the genuine air cleaner box fixed, andsettle the ignition coil bracket with the genuine
mounting bolt.
Tightening torque:10 N･m (1.0 kgf･m)‑8‑◇Install a supplied plate, and attach two bolts.
◇Loosen a rear axle nut and chain adjuster nut.
◇Fit the master link from inside to connect the drive

Oct./21/ 10

● Cautions Before Running
１ About fuel:◇ High-octane gasoline should always be used.
◇ Always replace the gasoline with high-octane gasoline when regular gasoline is remaining in the fuel tank.

Driving
direction

２ Additional hardware to be installed:

CO
Clip

◇Attach a clip.
※Be sure to attach the clip with its end-gap in the
opposite direction of driving.

◇ For driving your bike with this kit installed, the following hardware need to be installed additionally. We disclaim all responsibility for
any consequential and incidental damages or any other losses arising from the use of the provided products or parts, if your bike is
not equipped with these additional hardware.

２―１ Oil pump:

The installation of this kit increases the heat release value of the engine, set off by the increase in power. The installation of Super
Oil Pump is essential in order to circulate large amounts of oil and to help cool hardware and to alleviate the burden.

Essential Super Oil Pump
Part No.:01-16-0051

２―２

Clutch:The stock clutch cannot respond to the high engine power, and, therefore, causes clutch slippage, and consequently cannot transmit theengine power fully to the driving side.
Therefore, it is necessary to install a heavy duty clutch.

◇Fully tighten the loosely-tightened bolt on the drive
sprocket.
Tightening torque:12 N･m (1.2 kgf･m)
Tool:
Socket, 10mm

Part No. : ０２―０１―０２０２ (Primary reduction gear ratio remains the same.): ０２―０１―０２１４ (The primary reduction gear ratio is changed to 18 / 67 from 16 / 69.)

３ Change of sprocket

PY

Extension (small)◇ The installation of this kit will increase the power of your vehicle. So with the stock sprocket, you will find it uncomfortable to drive◇Install the removed (L) crankcase cover (※1) andstep bar.

※1 : Never forget to attach a dowel pin back to the(L) crankcase cover or a coupler.
◇Adjust the drive chain.

１４．Installation of an F.I. controller.
◇Install the controller following the installation
procedures for the F.I. controller.

１５．Installation of leg shield.

your bike because of too low gear, and will cause severe wears of hardware, not only adversely affecting the engine life, but also
possibly breaking the engine in the worst case. Therefore, please replace the drive and driven sprockets to make the gear ratio high.
※ Please note that a sprocket is not included in the kit.
※ Furthermore, the gear ratio of the sprocket changes according to the clutch type and wheel size. The list below is just for yourreference because the configuration in the list below needs to be changed according to the driver’s weight, purpose of use, desire,taste and the like.
※When changing the driven sprocket, remove hardware around the rear wheel. Raise the rear wheel off the ground by placing a racing
stand under the engine for safe work.

Recommended sprocket for use with S-Stage (with a driver weighing 65 kg)
ModelsSpecifications

Rear wheel size
8 inchMonkey (FI)

10 inchClutchTransmission

ManualHeavy-duty special
ManualHeavy-duty special

4-speed
4-speed
4-speed
4-speedRecommended Sprocket
Drive sprocket
Driven sprocket(Front)(Rear)
16
23
16
25
16
25
16
28

◇When the stock sprocket is changed to the recommended driven sprocket, the drive chain becomes too slack or too short. However,
it is impossible to take up the slack of the drive chain just by adjusting the free play. You need to either shorten the chain by cutting
it with a chain cutter, or to prepare a new drive chain.
※ The “Heavy-duty special clutch” described above refers to our special clutch and that of Item No. 02-01-0214 with the primary
reduction gear ratio changed to 18 / 67 from 16 / 69.

● F. I. Controller settingSpecification of the engine
Air filter kit ＋ the stock exhaust system
Air filter kit ＋ TAKEGAWA s Z-style exhaust system
Air filter kit ＋ TAKEGAWA s basic exhaust system

F.I.controller setting
７

Ｂ
Ｂ◇Install a front fender.
Tightening torque: 12 N･m (1.2 kgf･m)
Tool:
Socket, 10mm & Extension (small)● About F.I. controller:
Be sure to start the engine only after the installation of the F.I. controller. If you start the engine without the installation of the F.I.
controller, the air-fuel ratio will become so thin that the major malfunction of the engine may take place.

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‑9‑Oct./21/ 10