φ 27 Type-1 Front Fork + Disk Brake Kit for 10 inch Wheel(for bar handle Fork width 174mm / Offset 60mm)

CO・Thank you for purchasing one of our products.
Please strictly follow the 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
TAKEGAWA dealer.
◎ Please note: Illustrations and photos may vary from actual
hardware.

Item No. ：０６−０１−００３８ (Standard disk rotor)：０６−０１−００３９ (Floating disk rotor)
Fitting models and frame No.:
Monkey・Gorilla ：Z50J-1300017〜：AB27-1000001 〜：AB27-1900001 〜
Monkey (FI)Features○ Fork width 174mm, Offset 60mm.
○ 60mm offset can extend the wheelbase and increase the stability.
○ Machined and lightweight triple clamp.
○ Buffed and polished finish.
○ Included handle bar holder○ Anodized stem nut.
○ Included steering lock bracket.

PY

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 instructionsin this Instruction Manual.
◎ 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 and Gorilla.
◎ This Kit is for 10inch wheels only.
◎ For installation of this Kit, either an tube-type 10-inch aluminum wheel (Item No. 06-09-033 / 054) is required.
◎ A headlight stay, turn-signal stay, or steering handle are not included in this Kit, which are all extra-cost options.
◎ Please use our aluminum headlight stay of either 09-03-007, 008 or 09-03-07S.
◎ This Kit cannot be used with a stock throttle for a stock-specification carburetor. Therefore, it is necessary to prepare a HONDA’s genuine throttle.
◎ Please fill the brake fluid to upper level of master cylinder.
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.)

CAUTION

The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the

WARNING 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 brake disc 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 cause accidents.
◎ 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./08/ 15

▽▽◎ The following our parts are necessary for changing the front brake to a disk type, using this Kit. This mirror adaptor is needed only when a genuine
mirror or a mirror with an 8mm thread is used.
A mirror with a 10mm threadThis mirror adaptor is needed only when a genuine mirror or a mirror with an 8mm thread is used.

▽◎If the front brake is changed to a hydraulic disk, it is necessary to remove a standard throttle housing (a brake integrated with a lever) because a front
master cylinder needs to be installed. Therefore, either our TAKEGAWA-made high throttle set or a HONDA’s genuine part is necessary.
Our products:
Standard high throttle set Outer length: 710 mm, 09-02-0222, or Outer length: 810 mm, 09-02-0221 is for carburetor-type Monkey.
High throttle of 09-02-0223 is for FI Monkey.
90-degree-bent high throttle set Outer length: 700 mm, 09-02-021
Involue high throttle set Outer length: 710 mm,
Body: in black / 09-02-0230,
in gun metal / 09-02-0232
Outer length: 810 mm,
Body: in black / 09-02-0231,
in gun metal / 09-02-0233
HONDA’s genuine parts:
Throttle housing (1 piece)(53168-166-000)
Throttle housing (1 piece)(53167-GE4-000)
Pan screw, 5 x 22 (2 pieces) (93500-05022-0G)※ These products are for use with a standard carburetor or our KEIHIN PC18 carburetor.
▽

CO
▽

▽

◎ In the case of installing this Kit to motorcycles with frame Nos Z50J-1300017 to 1510400, the following parts are additionally needed.
For a motorcycle with a centrifugal clutch:
Combination switch assembly
For a motorcycle with a manual clutch:
Clutch lever and combination switch assembly１

０６―０２―１０１９

３

６

１２Ａ、Ｂ

１０
１３

１４

８
１６

１９

４
５

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

７

１５

２３

２８

２７

９ ２４

２１ ２２ ３１ ３２
３４

０６―０２―１００５

１７
１８

０６―０９―１３０６

０６―０２―００１７

０６―０２―１０１３

２

１１

PY

Kit consists of:Part Name
Left-side front fork assembly
Right-side front fork assembly
Fork top bridge
Upper handle holder
Lower handle holder
Steering stem
Steering lock bracket
Stem nut
Stem nut washer
Front axle shaft
Front wheel hub COMP.
Bearing 6201LLB
Distance collar
Disk rotor (Standard)
Disk rotor (Floating)
Disk bolt
Collar, 7.5 mm
Wheel spacer, 1 mm
Front brake master cylinder assembly
Sub-cord
Front caliper assembly

Qty
1
1
1
2
2
1
1
1
1
1
1
(2)
(1)
1
1
3
1
1
1
1
1

Repair Part Item No.
52522-181-T00
51422-181-T00
54411-165-T00
54412-165-T00
53601-GEF-T00
54303-165-T00
90503-165-T00
44301-GEF-T10
44604-181-T00-C
00-00-0077
44621-181-T00
45230-181-T50
45220-AB7-T00
90105-165-T00
44310-181-T00
44600-181-T00
06-08-1168
37600-KCZ-T00
06-08-115

２５

in packs of
１
１
１
１

１
１
１
１
1
1
1
1
1
1
１
１
１
１
１

No.
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38

３５

２６ ２９ ３０ ３３

３６Part Name
Front caliper bracket
Brake hose, 775mm
Banjo bolt, 10 x 1.25
Flange bolt, 6 x 15
Socket cap screw, 6 x 12
Socket cap screw, 6 x 20
Socket cap screw, 6 x 50
Socket cap screw, 8 x 12
Socket cap screw, 8 x 25
Flange socket cap screw, 8 x 20
Hex bolt, 6 x 10
Plain washer, 6 mm
Sealing washer, 10 mm
Banjoe (straight)

Banjoe (25°)
Brake fluid (BF-4)
Hex wrench, 5 mm
Hex wrench, 6 mm
Hex wrench, 10 mm
Insulation lock, 200 mm

Qty
1
1
2
2
2
2
4
2
2
4
4
1
4
1
1
1
1
1
1
2

３７

３８

Repair Part Item No.
45210-181-T00
06-080-0007
00-07-0007
00-00-0114
00-00-0116
00-00-0043
00-00-0044
00-00-0047
00-00-0075
00-00-0238
00-00-0307
00-00-0086
00-07-0010
00-07-0006
00-07-0037
06-08-0019

in packs of
１
1
1
4
6
10
3
4
4
4
10
10
10
1
1
1

00-00-0179

10※ 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 takethem in the quantity packed.
※ NO.12A is for Item No.06-01-0038, and 12B is for 06-01-0039.
‑2‑

Oct./08/ 15

〜 Installation Instructions 〜Disassembly:

Assembly:

１．Loosen an axle nut on the front
wheel.
２．Before starting the work, standyour bike securely on a rear

１３．Install the steering lock bracket
to the steering stem with a 6x12
socket cap screw.

COmaintenance stand placed on asuitable pedestal under theengine.
※ Choose a pedestal of a height
so the front wheel is just off theground.
３．Unfasten a pan screw from theheadlight, and disconnect thecables of a stop lamp switch
and turn signal switch.
４．Unfasten a pan screw from thethrottle housing to remove thethrottle housing and throttle
pipe.
５．Unfasten a pan screw from theturn-signal switch to remove theswitch.
６．Unfasten right and left bolts on
the headlight case to remove theheadlight.
７．Remove a horn and turnsignals.
８．Pull out an axle shaft anddetach a front wheel.
９．Unfasten a nut on the lower

handle holder at the back of the
top bridge, and demount asteering handle assembly.
１０．Unfasten a fork bolt, stem nut
and washer to remove the top
bridge.
１１．Remove a top thread andthen a fork assembly.
※ Be careful not to lose
bearing balls.
１２．Remove a handle lock from astock steering stem, which
please attach to a steering
lock bracket.
Caution: Apply the specified
torque.
Torque: 9 N・m (0.9 kgf・m)

Caution: Apply the specified torque.
Torque: 12 N･m (1.2 kgf･m)

１６．Fit the steering stem into thehead pipe, and finger tighten the
top thread as tight as possible.
Move it several times to the right１９．Routing the wire harness inthe same way as the stock
one, fit the top bridge into thefront fork and stem shaft. And

and left so the bearing may fit
right. Give it 1/8 turns backward
and check that it moves
smoothly and without rattling.

attach the stem washer andtighten the stem nut to thespecified torque.
Caution: Apply the specified
torque.
Torque: 59 N･m (6.0 kgf･m)

１４．Remove a bottom cone raceon the steering stem with apunch driver or a chisel, anddetach a dust seal and dust seal
washer.
And attach the dust seal
washer, dust seal, and bottom
cone race to the duralumin stem
shaft.

PY
１７．Fit the front fork to the steeringstem with the whirl stop on theaxle holder on the right viewed

Bottom cone racein the direction of travel. And
tighten an 8x20 steering-stem
split clamp bolt loosely for the
moment.

Dust seal
Dust seal washer

２０．Loosen the split clamp bolton the steering stem, andadjust the right and left innertubes to protrude in the samelength.

１５．Apply grease to the top cone
race and bottom cone race, andattach the bearing to thesteering stem and head pipe,
and then the top cone race tothe head pipe.
※ In case the balls are not set in
the bearing, then install 21 balls
each to the bottom cone raceand top cone race.
Before applying grease, firstwash the bearing with wash
oil. Be careful not to let the dirt
adhere to the bearing.

Whirl stop

１８．Fit the front fork on the left sidein the same way as you fitted iton the right side.
※ In case a front-fork clamp-type
headlight stay is used, fit theheadlight stay into the front
fork.

２１．Tighten the split clamp bolton the steering stem to thespecified torque.
Caution: Apply the specified
torque.
Torque: 26 N･m (2.7 kgf･m)

２２．Tighten a 6x20 split clamp
bolt on the top bridge to thespecified torque.
Caution: Apply the specified
torque.
Torque: 12 N･m (1.2 kgf･m)‑3‑

Oct./08/ 15

２３．Fit a steering handle pipe into
the handle holder and install
it to the top bridge. Tighten a
6x50 socket cap screw on
the handle holder tothespecified torque.
Caution: Apply the specified
torque.
Torque: 12 N･m (1.2 kgf･m)※ If you install the horn onto thesteering stem using a stock front
fender, place the horn inbetween the front fender andsteering stem. Install a washerof about 1.5 mm in thickness inanother clearance between
front fender and steering stem,and tighten it with a 6x15 flange
bolt.

CO
※Tighten the handle holders tobe spaced equally in the front
and at the back.

２４．Install to the steering handle
a master cylinder assembly,
turn signal switch(or, combination switch), andleft-hand grip.
Caution: Apply the specified
torque.

12 N・m (1.2 kgf・m)
for a flange bolt on themaster cylinderassembly

Caution: Apply the specified torque.
Torque: 12 N･m (1.2 kgf･m)

Horn
Stock fender

３０．Fasten the caliper to the caliper
bracket with an 8x12 socket cap
screw.
Caution: Apply the specified torque.
Torque: 25 N･m (2.5 kgf･m)

Caution: Apply the specified
torque.
Torque: 12 N･m (1.2 kgf･m)

３３．Pass a sealing washer, abanjo (straight), and asealing washer in this orderthrough a banjo bolt, and fix
and tighten it temporarily to amaster cylinder.

３４．On the front caliper side, fix
and tighten a banjo (2.5 °)temporarily in the same way
as above.

※ Apply thread lock to the threadof the bolt.

WasherPY

２６．Unfasten the nut holding thefront wheel hub and wheel totake them apart.
２７．The disc rotor is attached tofront wheel hub, tighten bolt byapplying a Loctite agent to disk
bolt to specified torque.
Caution: Apply the specified torque.
Torque: 25 N･m (2.5 kgf･m)

２５．Install a horn.
(The photo below shows thehorn attached to the steeringstem.)※In installing the horn to thesteering stem, fold back thestay as shown in the photo
below, and fix it by tightening
a 6x15 flange bolt to thespecified torque.

２９．Place the caliper on the disk
rotor.

２８．Install and tighten loosely for
now a front wheel hub to a
10inch aluminum wheel with a
8 x 20 flange cap screw.
※ In the case of using astandard offset wheel of
06-09-033 / 054
Place the supplied spacer
between the front wheel hub
and aluminum wheel.
Be careful to set the air valve to
be on the left side when seenin the direction of travel.

３１．Mesh a notch on the caliper
bracket with a convex portion
on the front fork, and put theincluded axle shaft into the front
fork from the right when viewed
in the direction of travel, andtighten them loosely for now.

Axle shaft

３２．Tighten up the flange cap screw
holding the wheel and hub.
Caution: Apply the specified torque.
Torque: 25 N･m (2.5 kgf･m)

３５．Fix a brake hose to eachbanjo. After determining abanjo-mounting angle andhow to connect the brakehose, tighten the banjo bolts
and brake hose fittings to thespecified torque.
Caution: Apply the specified
torque.
Torque: fittings
6 N・m (0.6 kgf・m)※A brake hose must not be
connected too tight tohamper the smooth steeringor interfere with the front
forks.
３６．Secure the brake hose withan insulation lock so it does
not interfere with other parts,and cut off the excess
portion of the hose with anipper.
※Fix the brake hose rather longor with some allowance so
the hose does not stretch tootight when the motorcycle
bounds or rebounds.
Caution: Apply the specified
torque.
Torque: Banjo bolt
15 N・m (1.5 kgf・m)

Front wheel hub
assembly.

mm
About 40

SpacerWheel‑4‑

Oct./08/ 15

３７．Connect the cables of thestop switch sub-harness andturn-signal switch(combination switch).
※ When installing onto theMonkey (FI model), connect
the stop switch sub-harness
and a sub-cord, and thenconnect the winker sub cord
and the stop switch harness
from the main harness.
３８．Demount the motorcycle fromthe rear maintenance standand pedestal.
３９．Tighten the axle shaft.

How to change front fork oil:
１．Loosen a fork top bolt.
２．Remove the socket cap screw on the side of the axle shaft.
３．Remove a front axle shaft.
４．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.
５．Pull out the axle shaft to detach a front wheel.

CO
Caution: Apply the specified
torque.

Torque: 60 N･m (6.0 kgf･m)

４０．Tighten up the socket cap
screw on the front fork.

Caution: Apply the specified
torque.
Torque: 20 N･m (2.0 kgf･m)

６．Loosen the split clamp bolts on the top bridge and stem to detach a fork.
７．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.
８．Expand and contract the inner tube to drain the fork oil.
(Leave the inner tube facing downwards for a few minutes.)
９．Stand the front fork to inject fork oil.
2
Fork oil viscosity; 40 mm /s (ASH-40)
Fork oil amount: 75 cc per front fork

Oil level: 75 mm※ Replace the fork oil either with ASH-40 or other manufacture’s No. 10 or 15.
※ Expand and contract softly the inner tube a few times to remove the mixed air from the oil.
While contracting the inner tube to the maximum, measure the oil level only after the oil surface has become still.
１０．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 for the moment.
１１．Install the front fork to the stem and top bridge, and tighten the split clamp bolt loosely for now.
１２．Tighten the top bolt to the specified torque.

PY

Caution: Apply the specified torque.
Torque: 20 〜 24 N・m (2.0 〜 2.5 kgf・m)

Socket cap screw

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

１３．Tighten the split clamp bolts on the steering stem and top bridge to the specified torque.
Caution: Apply the specified torque.
Torque: 26 N・m (2.7 kgf・m) for steering stem,
12 N・m (1.2 kgf・m) for top bridge

１４．Install the front wheel in the reverse order of disassembly.
Caution: Apply the specified torque.
Torque: 60 N・m (6.0 kgf・m) for axle shaft

20 N・m (2.0 kgf・m) for socket cap screw

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‑5‑Oct./08/ 15

How to bleed air from the brake system
Warning:

Caution:CO○ Do not allow any foreign materials to enter the system when filling thereservoir.
○ Always use fresh DOT 4 brake fluid from a sealed container whenservicing the system.
○ NEVER reuse the drained brake fluid.
○ Always use new sealing washers.
○ Avoid spilling fluid on painted, plastic, or rubber parts, otherwise it willcause damage. Place a rag over these parts whenever the system isserviced.
○Once the hydraulic system has been opened, or the brake hose has been
removed, or if the brake feels spongy, or if the air entered the system, thesystem must be bled.
○ Make sure that the specified torque is always correct.
○ Always use the designated brake fluid only.

○Keep grease off of brake pads and disc.
○If occurred, please change the pad and wipe it off from the disc.
Always use new ones whenever the parts are worn or damaged.

○ Make sure that the mastercylinder or reservoir is parallel tothe ground, before removing thereservoir cover and cap.

○ Pump up the system pressure withthe lever until there are no air
bubbles in the fluid flowing out thereservoir small hole and leverresistance is felt.

○ Connect a clear bleed hose to thebleed valve and receive thedrained fluid in a catch can.

PY

①Pump the brake lever several times,
then squeeze the brake lever all theway and loosen the bleed valve 1/2
turn.
Wait a few seconds and close thebleed valve.
② Release the brake lever slowly and wait a few seconds after it reaches
the end of its travel.
DO NOT release the brake lever until the bleed valve has been closed.
③ Repeat the steps 1-2 until there are no air bubbles in the bleed hose.
○After bleeding air completely, tighten
the bleed valves to the specified○Fill the master cylinder with DOT 4
brake fluid to the upper level.
Caution : Never allow
contaminates(dirt,
water, etc.) to get into
an open reservoir.
Caution：DO NOT mix different
types of fluid.

torque.

Caution: Be sure to follow thespecified torque.
Torque: 6 N・m (0.6 kgf・m)○Fill the brake fluid to keep the
specified level.

○ Install the diaphragm and reservoir
cover.
Tighten the reservoir cover screws
properly.
○Pump brake lever several time
before you ride.

☆ Check the level of the fluid in thereservoir and refill to prevent the
air from entering.

Caution: Never let in the dust or
water.
Caution: Do not use brake fluid,
mixing different types of
fluid.
DOT 4 Brake oil

Brake lever

CO

About the use of master cylinder

About the use of master cylinder

When you dismount the lever from the master cylinder, the looseness ofWhen you dismount the lever from the master cylinder, the looseness ofthe piston and the lever might be changed.

the piston and the lever might be changed.

In that case, rasp the shaded area of the lever and adjust.

In that case, rasp the shaded area of the lever and adjust.

PY

Co.,Ltd.

Co.,Ltd.
Feb./20/ 13

Feb./20/ 13

Feb./20/ 13

Feb./20/ 13

Co.,Ltd.

Co.,Ltd.

In that case, rasp the shaded area of the lever and adjust.

In that case, rasp the shaded area of the lever and adjust.

the piston and the lever might be changed.

the piston and the lever might be changed.

When you dismount the lever from the master cylinder, the looseness ofWhen you dismount the lever from the master cylinder, the looseness of

About the use of master cylinder

About the use of master cylinder