φ 30 Front Fork & Front Drum Brake Set Instruction Manual

CO(Fork width 198mm / Offset 60mm)

・Thank you for purchasing one of our products.
Please strictly follow the instruction to install and use the Kit.
・Before installing the Set, please be sure to check the Set contents.
If you have any questions about the Set, please contact your local TAKEGAWA dealer.
◎ Please note: Illustrations and photos may vary from the actual hardware.

Item No.：０６−０１−０７２９
Fitting model and frame No.:
Monkey and Gorilla ：Z50J-1300017〜：AB27-1000001 〜：AB27-1900001 〜Monkey (FI)

Safety Precautions for Use

・This kit not included other than Front fork and Triple clamp.
・You need 10” inch wheel and other parts.

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

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・Make sure before starting the installation that the motorcycle is secure on level ground.
・Always use a torque wrench to tighten bolts and nuts securely to the specified torque to avoid these parts getting damaged or loose.
・Do the installation with right tools.
・Please take note that a top bolt may come flying, sprung by a fork spring when unfastening a fork top bolt.
・As some products and frames have sharp edges or protruding portions, work with your hands protected to avoid injuries.
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 accidents.)
・Before riding, be sure to check every section for slack in parts like screws, and oil leak. 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 abnormality could lead to accidents.)
・Make sure to degrease brake shoe and drum before you ride.
・We recommend that the brake be installed by a qualified motorcycle technician at a well-equipped facility. (Otherwise, accidents may take place.)

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◎ The following TAKEGAWA-made parts are required for the use of this product:
A mirror with a 10mm thread (in packs of one)
Oval slide-type mirror (06-01-110)
NC31-type mirror (06-01-111)
Rectangular slide type mirror (06-01-112)
Mini mirror (right-hand mirror only) (06-01-113)◎ The brake cable included in this Kit cannot be installed onto a stock brake lever. Therefore, please separately purchase our brake lever.
Our products:
Quick lever assembly (06-08-3005)
Brake lever (06-08-300)◎ It is necessary to remove a stock throttle housing (integrated with a brake lever). Therefore, either our high throttle set or a Honda’s genuine part isneeded, which are compatible with the installed carburetor
In case our carburetor kit of PD22, PE24, VM26 or PE28 is used:High throttle set (cable length: 810 mm) (09-02-0221, 09-02-0231 or -0233)
High throttle set (cable length: 710 mm) (09-02-0222, 09-02-0230 or -0232)
In case a stock carburetor, or our carburetor kit of PC18, PC20, PD22, or PE24 is used:(In the case of PD22 or PE24, a high throttle can be used.)
Honda genuine parts
Throttle housing (1 pc) (53168-166-000)
Throttle housing (1 pc) (53167-GE4-000)
Pan screw, 5 x 22 (2 pcs) (93500-05022-0G)※ A genuine throttle cable cannot be used on a motorcycle with a frame No. Z50J-130017 ~ 1510400.
If a stock carburetor is installed, a cable complete and throttle of 17910-165-640 are required.
◎ In installing this product onto a motorcycle with a frame No. Z50J-1300017 ~ 1510400, the following parts are additionally needed.
For a centrifugal clutch motorcycle:
Combination switch assembly (02-01-015)
For a manual clutch motorcycle:
Clutch lever & combination switch assembly (02-01-016)‑1‑Dec./15/ 10

Features・The wide stem type φ 30 front fork assembly (60mm offset type), can extend the wheelbase and increase the stability of the front wheel.
・198mm width and 60mm offset triple clamp can installation of 3.5J wide rims.
・Light weighing machining.
・A stock steering lock, oil cooler, meter and bracket can be fixed to the steering stem.

CO◎ 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.
◎ 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.
◎ This manual should be retained for future reference.

Kit includes:

０６―０１―０７２３

０６―０２―００１６０６―０２―１０００１２

３０６―０２―１００１

５ ４６１５１０PY

１４１１６ １１０６―０２―１００５
９００―０６―００４６

１３ １２

７０６―０８―３０３２８１７１８８２０１９１６２１２３Repair Part Item No.

in packs ofNo.

２２２４ ２５Part Name

２６ ２７２９No.

Part Name

Qty

Qty

Repair Part Item No.

1

Right side front fork assembly

151400-GEF-T10

116 Front brake cable, 940 mm

145451-165-T20

in packs of
12Left side front fork assembly

151500-GEF-T10

117 Brake arm

13Top bridge

118 Flange bolt, 6 x 25

100-00-0115

54Steering stem nut

154303-165-T00

119 Sub-cord

137600-KCZ-T00

15Stem nut washer

190503-165-T00

120 Front fender stay

261110-181-T00

16Socket cap screw, 6 x 20

200-00-0043

1021 Fender stay collar

461111-181-T00

17Upper handle holder

254411-165-T00

122 Front axle

144301-GFL-T00

1

8Lower handle holder

254412-165-T00

123 Button head cap screw, 6 x 15

400-00-0132

49Socket cap screw, 6 x 50

400-00-0044

324 Button head cap screw, 6 x 10

400-00-0092

510 Steering stem COMP.

125 Hex nut, 6 mm

400-00-0128

1011 Socket cap screw, 6 x 25

400-00-0089

1026 Plain washer, 6 mm

400-00-0086

1012 Steering lock bracket

153601-GEF-T00

127 Hex wrench, 4 mm

113 Socket cap screw, 6 x 12

200-00-0116

628 Hex wrench, 5 mm

114 Front brake cable bracket

145220-GFL-T01

129 Hex wrench, 6 mm

115 Flange cap screw, 8 x 30

200-00-0352

2※ 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.
‑2‑Dec./15/ 10

〜 Installation Instructions 〜
１．Before starting the work, stand yourmotorcycle securely on a rear maintenancestand and secure the engine on a suitablepedestal.

６．Install the steering stem on the steering head,
and then install the upper bearing race and thesteering stem adjusting nut on it. Then, tighten
the steering stem adjusting nut fully by hand.
Move the stem four to five times to the right andleft. After the steel balls have fit in all right, thenCO

１１．Install the brake cable on the bracket.
Caution: Apply the specified torque.
Torque: 6 N・m (0.6 kgf・m)tighten the top thread to the specified torque.

Caution: Apply the specified torque.
Torque: 2 N・m (0.2 kgf・m)

２．Remove the steering lock from the steeringstem, and install it on the steering lock bracket.

※ Check that the steering stem moves smoothly
without being shaky.

１２．Replace stock brake arm to Takegawa's

Caution: Apply the specified torque.
Torque: 9 N・m (0.9 kgf・m)

brake arm.
Caution: Apply the specified torque.
Torque: 10 N・m (1.0 kgf・m)

７．
Remove the engine stand. Install the top bridge,

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and fasten the stem nut with a washer temp
orarily.
８．Tighten the stem nut to the specified torque.

３．Install the steering lock bracket on thesteering stem COMP. with a socket cap screw.
Caution: Apply the specified torque.
Torque: 12 N・m (1.2 kgf・m)

Caution: Apply the specified torque.
Torque: 59 N・m (6.0 kgf・m)

１３．Install front wheel.
１４．Meter gear, wheel hub and drum brakeplate install with axle shaft.
１５．Install front brake cable.

９．
Install the φ 30 front fork. Tighten the top bridge
and the clamp bolt to the specified torque.

４．Remove the lower bearing race of thesteering stem with a punch driver or a chisel,and remove the dust seal and the dust seal
washer. Install the dust seal washer, the dustseal, and the lower bearing race on thesteering stem COMP.
５．Apply the grease well to the upper and lower
bearing races, and install the ball bearings.
※ The ball bearings should be washed before
installing, and keep from dusts.

Apply grease.

Caution: Apply the specified torque.
Torque: 15 N・m (1.5 kgf・m)

１０．Attach the front brake cable bracket.
Caution: Apply the specified torque.
Torque: 23 N・m (2.3 kgf・m)

Steering stem
Upper bearing race
Ball bearings

１６．Put a collar in between the front fender
stay and bottom case, attach the 6x15
button head screw, and tighten it to thespecified torque.
Caution: Apply the specified torque.
Torque: 10 N・m (1.0 kgf・m)
CollarBall bearings
Lower bearing race
Dust seal
Dust seal washer‑3‑Dec./15/ 10

１７．Set the optional front fender in between
the fender stays.
Put a 6x10 button head screw into thefender stay, and attach a plain washer andhex nut from the back of the fender tosecure the screw. Holding tight the hex nut

How to change front fork oil
１．Loosen a bolt on the top bridge and the stem toremove the forks.
Remove the forks only after loosening the fork
top bolt.
２．Unfasten the bolt being careful not to send thetop bolt flying out.
Prepare an oil pan, and turn the fork upside
down. And detach the collar, joint plate andspring.

COwith a spanner, tighten the screw to thespecified torque.

Caution: Apply the specified torque.
Torque: 7.8 N・m (0.8 kgf・m)※ For the installation of the front fender,
please refer to its instruction manual.

１８．Place the optional steering handle pipe inbetween the handle holders, and attach
them to the top bridge.
Tighten the socket cap screws on thehandle holders to the specified torque.
Caution: Apply the specified torque.
Torque: 12 N・m (1.2 kgf・m)※Fasten the handle holders so the space at
the front and back is equal.
Please install the other parts referring toeach instruction manual enclosed in theproducts.
Handle pipe
Upper holder

BA

Lower holder

A=B

１９．Connect the cables of the stop switch
sub-harness and turn-signal switch(combination switch).
※ When installing onto the Monkey (FI model),３．Expand and contract the inner tube to drain thefork oil.
(Leave the inner tube facing downwards fora few minutes.)
４．Stand the front fork to inject fork oil.
Fork oil: No. 20
Fork oil amount : 155 cc per fork .

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５．
Wipe off the oil on the fork spring, and put in thespring with the narrower-pitched portion
facing downwards. Attach the joint plate andcollar, and tighten the top bolt loosely for now.

upward※ Beware of thedirection

downward

６．Attach the forks to the stem and top bridge, andtighten the top bolt to the specified torque.

Caution: Apply the specified torque.
Torque: 20 〜 24 N・m (2.0 〜 2.5 kgf・m)connect the stop switch sub-harness anda sub-cord, and then connect the sub cord
and the stop switch harness from the mainharness.

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‑4‑Dec./15/ 10