Instruction Manual for Disk Hub Kit for φ 27 Front Fork

CO(for 10-inch)
Item Nos：０６−０８―００２１ (Floating disk rotor)

Fits：０６−０８―１４３１ (Standard disk rotor)：Monkey

Frame Nos ：Z50J-1300017〜：AB27-1000001 〜・Thank you for purchasing one of our TAKEGAWA-made products. Please strictly follow the following instructions in installing and using the Kit.
・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.
◎ Please note that, in some cases, the illustrations and photos may vary from the actual hardware.

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 product not in conformity with the instructions

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in this Instruction Manual.
◎ 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.
◎ You are requested not to contact us about the combination of our product with other manufacturers’.
◎ For disassembly and installation, please be sure to refer to a HONDA’s service manual for the Monkey.
◎ This Kit is for 10-inch wheels only.
◎ For installation of this Kit, either an tube-type 10-inch aluminum wheel (Item No. 06-09-033 / 054) is required.
◎ Please use our TAKEGAWA’s front caliper.
◎ This kit is for changing a cast wheel hub to die-cast wheel hub.

CAUTION

The following show the envisioned possibility of injuries to human bodies and property damage as a result of disregarding thefollowing cautions.

・Before starting installation, make sure that your bike is secure on level ground.
・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.)
・Do the installation with right tools. (Otherwise, breakage of parts or injuries to you may take place.)
・When unfastening a fork top bolt, please take note that there is a danger of the fork top bolt coming off flying, sprung by a fork spring.
・As some products and frames have sharp edges or protruding portions, please work with your hands protected.
(Otherwise, you will suffer injuries.)
・Work with care so the brake fluid will not get on your skin. After the work, rinse your hands thoroughly with plenty of water.
(Otherwise, your hands may get rough and dry.)・Work with utmost care because the brake fluid will deteriorate or damage the painted surface, resin components, or rubber products if the fluid
adheres to them. In this case, rinse the fluid-adhered portions with water without any loss of time.
(Otherwise, this may cause the deterioration or damage of the parts.)
The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding theWARNING following warnings.

・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 and subsequently to overturning or accidents.)
・Before riding, always check every hardware like screws for slack. 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.)
・Before riding, always check every hardware like screws for slack and oil leakage. Besides, when you notice something abnormal with yourmotorcycle while riding down a road, stop riding immediately, park your motorcycle in a safe place, and check what has gone wrong.
If something has gone wrong with your motorcycle, NEVER keep on riding without fixing your bike.
・Use only the specified brand of brake fluid. Do not mix different types of fluid, as they are not compatible with each other.
(The blended use of fluid may cause technical troubles or chemical change.)
・Do not get a brake disc rotor or brake pad oil-stained. If they are oil-stained, replace the brake pad with a new one, and degrease the brakedisc rotor. (Otherwise, these oil-stained parts may cause accidents.)
・Get the brakes installed by a skilled mechanic at facilities with special instruments and tools. Otherwise, the wrong installation will causeaccidents.
◎ Please be informed that, mainly because of improvement in performance, design changes, and cost increase, the product specifications andprices are subject to change without prior notice.
◎ This manual should be retained for future reference.
‑1‑Oct./08/ 15

Kit consists of:
２Ａ、Ｂ
１３４

CO
７０６―０９―１３０６

６

８５No.
11-A
1-B
2A
2B
345678

Part Name
Front wheel hub COMP.
Bearing 6201LLB
Distance collar
Disk rotor (Standard)
Disk rotor (Floating)
Disk boltCollar, 7.5 mm
Wheel spacer, 1 mm
Front caliper bracket
Socket cap screw, 8 x 12Flange socket cap screw, 8 x 20

Qty
1(2)(1)
1
1
3
1
1
1
2
4Repair Part Item No.
44604-181-T00-C00-00-0077
44621-181-T00
45230-181-T50
45220-AB7-T00
90105-165-T00
44310-181-T00

in packs of
1
1
1
1
1
1
1

45210-181-T00
0-00-0047
00-00-0238

144※Please note that in ordering repair parts, be sure to quote the Repair Part Item No.
Otherwise, we may not be able to accept your orders.
There are some parts, however, for which we are not in a position to accept
your order in just the quantity to be used. In this case, please take them in thequantity packed.
※ NO.2A is for Item No.06-08-1431, and 2B is for 06-08-0021.

〜 Installation Instructions 〜

１．With reference to theinstruction manual for yourcurrent front wheel hub, remove
the front wheel hub.
２．The disc rotor is attached tofront wheel hub, tighten bolt byapplying a Loctite agent to disk
bolt to specified torque.

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７．Align the concave portion of thecaliper bracket with the convex
portion of the front fork.

４．Fix the disk rotor with disk bolts.
Caution: Apply the specified torque.
Torque: 25 N･m (2.5 kgf･m)

And pass the supplied axle shaft
from right to left, in the direction oftravel, through the front fork,caliper bracket, front wheel
assembly, meter gear, collar, andfront fork in this order. And tighten
them loosely for now.

５．Place the caliper on the disk rotor.

Caution: Apply the specifiedtorque.
Torque: 25 N･m (2.5 kgf･m)

６．Fasten the caliper to the caliper
bracket with an 8x12 socket capscrew.

an 8x20 socket cap screw.
※ When a stock offset wheel of
06-09-033 / 054 is to be used;
Place the supplied spacer
between a wheel hub
assembly and the wheel.
The air valve should face themeter cable.

Caution: Apply the specifiedtorque.
Torque: 25 N･m (2.5 kgf･m)

１０．Demount the motorcycle fromthe rear maintenance standand pedestal.
１１．Tighten the axle nut.

Caution: Apply the specified torque.
Torque: 25 N･m (2.5 kgf･m)
３．Install loosely the wheel hub
assembly onto the wheel with

９．Tighten up the flange cap screw
holding the wheel and hub.

※Apply thread lock to the thread ofthe bolt.

８．Adjust the height of the front

fender,and then tighten the bolt on
the bracket.

Caution: Apply the specified torque.
Torque: 5 N･m (0.5 kgf･m)

Caution: Apply the specifiedtorque.
Torque: 62 N･m (6.2 kgf･m)

１２．Let the air out of a brake.
※ Please see the attachedsheet for how to let the airout of a brake.

Front wheel hub
assembly.
SpacerWheel‑2‑Oct./08/ 15

How to change front fork oil:
１．Loosen a fork top bolt.
２．Loosen an axle nut on the front wheel, and detach only a nut.
３．Before starting the work, stand your bike securely on a rear maintenance stand placed on a suitable pedestal under the engine.
※ The work will be easier at the height obtained when your bike stands with the front fork stretched to the fullest extent.
４．Pull out the axle shaft to detach a front wheel.
５．Loosen the split clamp bolts on the top bridge and stem to detach a fork.
６．Detach a top bolt, being careful not to let it fly out. Prepare an oil pan, and stand the fork upside down to pull out the spring.
７．Expand and contract the inner tube to drain the fork oil.

CO(Leave the inner tube facing downwards for a few minutes.)
８．Stand the front fork to inject fork oil.
Fork oil : No. 20
Fork oil amount: 71 cc per fork
９．Wipe off oil on the fork spring, and put in the spring with the narrower-pitched portion facing downwards. Attach the top bolt and tighten it loosely forthe moment.
１０．Install the front fork to the stem and top bridge, and tighten the split clamp bolt loosely for now.
１１．Tighten the top bolt to the specified torque.
Torque: 20 〜 24 N・m (2.0 〜 2.5 kgf・m)
１２．Tighten the split clamp bolts on the steering stem and top bridge to the specified torque.
Torque: 26 N・m (2.7 kgf・m) for steering stem,
12 N・m (1.2 kgf・m) for top bridge
１３．Install the front wheel in the reverse order of disassembly.
Torque: 62 N・m (6.3 kgf・m) for axle nut

PYCo.,Ltd.
3-5-16 Nishikiorihigashi Tondabayashi Osaka Japan
TEL : 81-721-25-1357 FAX : 81-721-24-5059
URL : http://www.takegawa.co.jp‑3‑Oct./08/ 15

How to let air out of a brake
Warning:Notice:CO○ Do not get dust or water in the brake fluid when adding the fluid.
○ Do not use brake fluid, mixing different types of fluid.
○ NEVER reuse the used drained brake fluid.
○ NEVER reuse the used sealing washers.
○NEVER let the brake fluid adhere to the paintwork, plastics and rubber○Never let the oil or grease adhere to a brake-disk rotor or brake pad.
Should oil or grease adheres, degrease the rotor or change the pad.
○ In case you find damaged parts, be sure to replace them with new ones.

parts, as the fluid damages them.
○If the air gets mixed in the hydraulic system by, for example, removing
the brake hose, let the air out of the hydraulic system.
○ Always follow the specified torque.
○ Always use the designated brake fluid only.

○ Detach two flat pan screws on
the master cylinder assembly, andremove a master cylinder cap anddiaphragm.

○ Connect a transparent bleeder
hose to a bleeder valve on thecaliper, and receive the drained
brake fluid in the suitable cup
placed at the tip of the other end of
the hose.

○Keep holding the brake lever, tighten
the bleeder valve on the caliper.
○ Release the brake lever slowly, andkeep the lever in the fully released
position for a few seconds.
①Holding the brake lever, ease thePY
bleeder valve on the caliper by half
a turn. And tighten up the valve again.

② Release the brake lever slowly, and keep the lever in the fully released
position for a few seconds.
○ Repeat the above work of No.1 and 2 until no air bubble blows out of
bleeder valve.
☆Check the brake fluid level from time to time, and add the fluid when it isclose to the lower level mark.

○If the air is not mixed in the brake oil,tighten the bleeder valve to thespecified torque.

○ Add brake fluid to the upper levelmark in the oil cup in the mastercylinder.
Note: Do not get dust or water in.
Note：Do not use brake fluid,
mixing different types offluid.
DOT4 brake oil

Note: Be sure to follow thespecified torque.
Torque: 6 N・m (0.6 kgf・m)○ Add the brake fluid up to the upper
level mark in the oil cup. And installthe diaphragm and master cylinder
cap with a flat pan screw.

○ Ease the bleeder valve by half aturn. And repeat squeezing andreleasing the brake lever until thebrake fluid flows out of the bleeder
valve in large amounts.
☆ Do the work, paying heed to theremaining amounts of brake fluid.

Note: Never let in the dust orwater.
Note: Do not use brake fluid,
mixing different types offluid.
DOT4 Brake oil

As the case may be, add the brakefluid.

Brake lever