COEngine Complete KIT:☆Secondary kick starter engine☆ DESMO-124☆TAF 5 speed (Super Street)☆Special Clutch (wet)Item No.：０１―００―９４４０

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Compatible models
Monkey / Gorilla ：Z50J -2000001〜：AB27-1000001〜 1899999

Thank you for purchasing our Complete Engine.
This engine is one of our Engine Complete Series which we have designed and produced by using with years of our experienced product development and manufacturing know-how.
We are proud of that we guarantee customer satisfaction with such a lightweight and high power engine.
Before installing and using this product, please check the contents of the kit, read this installation instructions carefully and understand them completely.

Important Notice

１．Please Note: Illustrations and photos may vary from actual hardware.
２．The service and repair information contained in this manual is intended for use by qualified, professional technicians. Any person who does not have sufficient technique, knowledge, proper tools and equipment will neverwork. Be sure to ask specialty shops or professional mechanics.
Please ask for cylinder head maintenance by our factory.
Poor technique and lack of knowledge may cause the maintenance problems or damage parts.
３．This product is intended for use ONLY in closed racing course. Never use this product on public roads.
４．This kit is compatible with the above mentioned compatible models ONLY. Note: Do Not use this product for other models than listed above.
５．The cylinder length of this complete engine is longer than that of the stock engine.
It is impossible to install on stock motorcycle chassis. NOTE: Modification of the chassis is required.
６．Please note that mainly because of improvement in performance, design change, and cost increase, the product specifications and prices are subject to change without prior notice. We shall be held free and harmlessfrom any and all liabilities or claims for any defects of the parts / the product after installation, and use, and/or any other products/parts.
７．We do NOT accept any claims due to the parts for racing use only. Except, any requests for the return or repair of goods purchased from TAKEGAWA must be made within one month of receipt of goods against defects
in workmanship and/or materials originally caused by ONLY our failure. No returns or repairs will be accepted after one month. However, we DO NOT accept our products which are NOT installed in the right way and/or
DO NOT used properly.
We are not responsible for any expenses for repair or replacements.
NOTE: When you use for racing, we shall be held free and harmless from any and all claims.
８．These instructions should be retained along with this product.
‑A1‑

Oct./11/ 11

CORead all instructions first before starting the installation.

○ We do not take any responsibility for any accident or damage whatsoever arising from the use of this product not in conformity with the instructions in this Manual.
○ While working on this product, be sure to proceed with the proper work in accordance with the instructions.
○Be sure to prepare the genuine service manual of the compatible models and work as instructed. The service and repair information contained in this installation instructions and the genuine service manual are intended foruse by qualified, professional technicians.
Be sure that any person who attempts service or repairs without the proper experiences, tools and equipment ask specialty shops or professional mechanics.
○ We shall be held free and harmless from any and all liabilities or claims for any defects of the parts/the product after installation, and use, and/or any other products/parts.
○ Do not use other manufacture’s ignition parts, or it will cause the failure.
○ The necessary parts for this kit should be all TAKEGAWA-recommended parts. Always use our recommended parts.
○ Use TAKEGAWA-recommended fuel and engine oil.
○ Do not keep engine running in idle position for long period of time. It exceeds engine temperature, which cause the damage of the engine.

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CAUTION The following show the envisioned possibility of injuries to human bodies and property damage as a result of disregarding the following cautions.
・This Kit is designed for closed course competition purposes only. So please do not drive on a public road after the installation of this Kit.
・Before starting the installation, make sure the engine and muffler are cool at below 35 degrees Celsius. (Otherwise, you will burn you.)・Prepare right tools for the work. (Otherwise, the installation with improper tools could cause breakage of parts or injuries to you.)・As some products and frames have sharp edges or protruding portions, please work with your hands protected. (Otherwise, you will suffer injuries.)
・Always use new gaskets, seals and the like. The continued use of the worn or damaged ones will cause engine trouble.

WARNING

The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the 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 doing work, place the motorcycle on level ground to secure your motorcycle for safety's sake. (Otherwise, your motorcycle could overturn and injure you while you are working.)
・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.)
・As gasoline is highly flammable, never place it close to fire. Make sure that nothing flammable is near the gasoline. (Otherwise it may cause a fire.)・Tighten to a specified torque using a torque wrench. (Otherwise, improper tightening may cause the bolts or nuts to get damaged or come off, leading to accidents.)
・Never use the parts unspecified by us. (This may lead to parts breakage and consequent accidents)
・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.)
・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.)
・Carry out inspection and maintenance of your motorcycle correctly according to the instructions and guidelines in the service manuals. (Use TAKEGAWA-recommended fuel and engine oil.)・Fuel must always be high-octane gasoline. (Otherwise, troubles such as engine knocking may cause accidents.)
・When driving a bike, a driver must always wear a helmet securely. Otherwise, the driver is likely to be subject to death or serious injury in an accident.

‑A2‑

Oct./11/ 11

●About our DESMO headCO

Features●Use of Lightweight Outer Rotor ACG◇ Most 4 stroke combustion engines use a camshaft and a valve spring to open and close the valves, but the
DESMO structure uses a specially shaped camshaft that forces the valve open and shut.
Thus, since it does not use a valve spring, there is no surging of the valve spring when driving at high speeds.
And another special feature is the very small amount of friction exerted on the camshaft.
The cylinder head uses a twin cam of 4 valves, so the intake valve diameter is 22mm and the exhaust valve
diameter is 19mm.
Within the limited space of the horizontal engine, 8 rocker arms and 2 camshafts are distributed like a precision
instrument, providing proof-positive of the technical power of our company.
In addition, we have tested a large number of combustion chambers of differing shapes, and we have utilized
the shape with the highest efficiency ratio.
Mutual compatibility of the exhaust port and the exhaust system has been achieved by using the same as our
Super Head and stock head.
In addition, the cam gear related parts and the intake manifold are also compatible with the present DOHC
engine.

●Use of Plated Cylinder:◇SS-outer rotor is equipped as standard .Rotor body is a compact design and it weighs 536g. The best ignition
timing is set up exclusively for this complete engine and the quick response has been achieved.

●Forged piston◇Forgings are tougher and more durable, and will stand up to the abuse that high performance piston require.
It shaped during the forging process; its internal grain deforms to follow the general shape of the part.
As the result, forgings have condensed grain that is aligned to the features of the part, which produces

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higher mechanical properties, and resistance to impact and fatigue.

◇This cylinder is aluminum one-piece construction and the ceramic chrome plated inner wall allows the
additional wear-resistance and the reduced friction loss. It also features both high gas tightness anddurability.

● Use of Oil Jet:

◇ We have installed the oil jet which works to jet-spray the oil to the rear side of the piston from crankcase oilline in order to cool the piston.

● Use of Wet Multiple-Disk Clutch:◇We have installed a multiple-disk clutch with 5 disks onto the transmission main shaft so it can respond toeven high output powers.
This arrangement serves to improve durability of the crankshaft and throttle response. In addition, we haveinstalled a highly-reliable cartridge oil filter on the clutch cover. The clutch cover is so structured that a newline is prepared for taking out an oil cooler from the clutch cover and a thermostat can be installed as an
option.

● Use of close ratio transmission:◇ The close ratio transmission is designed to enable smooth shift up and down and cornering, and, moreover,effective transmission of engine power.
‑A3‑

Oct./11/ 11

１

CO
１０

９

３

〜 Kit contains 〜

１４

２
１２

７

８

４

５

１６

１１
６

１３

Part NameEngine COMP.
Spark plug, ER8EH
Intake manifold
Socket cap screw, 6 x 20
Socket cap screw, 6 x 15
Norma Torro Band
Inlet pipe gasket
Exhaust pipe gasket
Clutch cable COMP., 850 mm
Braided hose, 8 x 1 m
Hose clamp, 13.1
Spark plug cap COMP.
Plug cord joint
High tension cord, 500 mm
Hyper CDI
Head cover gasket set
Plug socket, 13mm
Ball point driver, 4 mm
Alumi special (5 g)

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

Repair Part Item No.

In packs of

NGK-ER8EH

30700-DSM-T00
00-01-1012
00-01-1043
05-03-0003
06111-DSM-T00
00-00-0247

1
1
2
2
1
1
2
1
1
2
1
1
1
1
1
1

00-01-0001

106171-D4H-T00

00-01-0064
00-02-0133
00-07-0070※Please order repair parts with the Repair Part Item No. Without the repair part item NO.,

１８

１７

１５

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

we may not be able to accept your orders.
Some parts are only available as a set. In this case, please order them with the set

number.

１９‑A4‑

Oct./11/ 11

rev.Aug./12/ 13

COMain Reference Value
4-cycle gasoline
Type
Displacement
123.7cc
Number of cylinder and arrangement Horizontal single cylinder
Cooling method
Air-cooling
Valve train
DOHC(desmodromic) valve, chain / gear drive.
Chamber design
Pentroof (Hemispherical) type
Bore and Stroke
54mm x 54mm
Compression ratio
12.5 : 1
Camshaft type
Valve timing:
IntakeopenclosedExhaust open
closedLubricating method
Pump type
Capacity

Intake 25
Exhaust 25(1mm lift)
20°BTDC
50°ABDC
50°BBDC
10°ATDC

High-octane gasoline（research method: over 97 octane value)

Ignition system
Spark plug

C.D.I. ignition
NGK-ER8EH

Starting method

Kickstarter systemrear-wheel-drive mechanism
Type

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Inspect and Adjust
Frequency
Every 200km
Every 500〜600km
Every 1000〜2000km
Each time
Every 1500〜2000km
Every 250km
Every 1000km
Every 1000km
Every 2000km
Every 1000km
Every 2500km
Every 2000km

Refer to page
P-C1
P-C1
Depend on Carburetor type
P-C2
P-C2
See Service Manual
See Service Manual
See Service Manual
See Service Manual
See Service Manual
See Service Manual※ Maintenance period in the table is a guideline. You might need to work more frequently
depending on the motorcycle usage or condition.
We recommend more frequently maintenance than the maintenance period.

Combined use of force feed system & splash lubrication system
Trochoid type
0.8 liter

Fuel to be used

Power transmission
ClutchOperating mode
Transmission
Type
Gear ratio
1st speed
2nd speed
3rd speed
4th speed
5th speed

Items
Clean and Inspect Spark Plug
Inspect Valve Clearance
Change Engine Oil
Adjust and Inspect Carburetor
Replace Oil Filter
Adjust Clutch Cable
Inspect Clutch Friction Disc
Inspect Piston and Piston Ring
Inspect Piston Pin
Inspect Crankshaft
Inspect Cylinder Head and Cylinder
Inspect Crankcase

Wet multi-disk
MechanicalConstant mesh, 5-speed return2.357 (33 / 14)
1.764 (30 / 17)1.400 (28 / 20)
1.136 (25 / 22)
1.000 (24 / 24)

Chain drive‑A5‑

Oct./11/ 11

CO〜 Precautions of Use 〜

About the specifications of motorcycle to equip

About upper limit of revolution:◇ The cylinder length of this complete engine is longer than that of the stock engine.
It is impossible to install on stock motorcycle chassis. NOTE: Modification of the chassis is required.
For Monkey / Gorilla, modify the chassis if necessary after checking whether the installation is possible◇Max rpm may vary by the camshaft and engine specification, always use taco meter to avoid over-rev theengine rpm.
124cc : Intake camshaft : 25
Exhaust camshaft : 20
Maximum rpm : 12000 rpm
138cc : Intake camshaft : 25
Exhaust camshaft : 25
Maximum rpm : 11500 rpm◇ Take note that engine racing and sudden acceleration, particularly in the 1st or 2nd gear, tend to exceed thereferring to the following parts and optional parts of P-D1 〜 D4.

Compatible Specifications Data Chart

Front Fork

Stock fork (Inapplicable) ×

Our φ30 Upright Front Fork

Spec Modification(See P-D4)

Tyre

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Larger wheel (10-inch) is recommended according to the power increase.

Top Bridge /Stock fork (Inapplicable) ×

Our Top Bridge & Stem Kit or Front Fork Kit

Steering stem

Spec Modification

60mm Offset (See P-D4)

upper limit of revolutions.
Over revolutions will result in nonsmooth revolutions of the engine, not only adversely affecting the engine
life, but also possibly breaking the engine in the worst case.

We recommend the modification to match the front fork and tire size.

Rear Fork(See P-D4)

We recommend to use it according to the heat increase.

Oil cooler(See P-D3)

Drive /

Stock (Inapplicable) ×

Final Gear Ratio 2.188〜2.063 (for 10-inch)

Driven sprocket

Spec Modification(See P-D2)

Oil catch tank

Need to Install

Equipped as necessary(See P-D4)

About fuel:●An Engine NO. (Serial No.) is stamped on this engine as identification.
Please specify your Engine NO. when ordering repair part or contacting us.

◇ Whenever regular gasoline is remaining in the fuel tank, always replace it with high-octane gasoline.

About oil cooler:◇The installation of this product increases the heat release value of the engine, set off by the increase inpower. We recommend you, therefore, to install an oil cooler kit, for a long-time high-load running, whichkeeps oil at appropriate temperatures and prevents such troubles as oil film shortage at high temperatures.
● In case you use the breather cap, be sure to use an oil catch tank at the same time.

Engine No.stamped here.
2SMS-20001 〜

Due to large displacement engine, blow- by gas volume may increase. Larger capacity catch can are highly
recommended. (approx 500 cc)

Co.,Ltd.
3-5-16 Nishikiorihigashi Tondabayashi Osaka Japan‑A6‑

TEL : 81-721-25-1357 FAX : 81-721-24-5059 URL : http://www.takegawa.co.jp
Oct./11/ 11

CO〜 Installation Instructions 〜☆ Before starting the installation, please prepare the relative service manual and necessary tools for the motorcycle.
☆ And prepare necessary optional parts as well. For details, please see the attached sheets.
☆ Caution: This installation instructions are for the models which this complete engine can be equipped.
☆ Please Note: Illustrations and photos may vary from actual hardware.
●Remove the engine○ Remove the engine and carburetor from the
motorcycle referring to the service manual of yourvehicle.

●Connect ACG●Installation of clutch cable:○Replace the CDI with the supplied CDI referring to the○Attach a clutch cable to the clutch lever, and routeservice manual of your vehicle.
○Connect the wire from Engine COMP and the couplerfrom the motorcycle.

the cable to the clutch cable receiver, being careful
not to stretch it too tight.

○ Turn the clutch release pinion clockwise until itcomes to a halt, and put the plain washer into therelease pinion.

Clutch release arm

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Clutch lever COMP.

☆ If you set up the main wire harness as a racing
purpose, connect the wires referring to the attachedwiring diagrams.
(See P-B6)

Arm spring

Clutch cable

Plain washer☆ For those who ordered without ACG
・Remove the generator cover and install thegenerator and flywheel following the instructionsof your ignition parts.

○ Attach the cable at cable receiver.

●Installation of engine○Install the engine COMP. to the frame referring to
the relative service manual for the motorcycle.
Caution : Be sure to follow the specified torque.
Warning : Do follow the instructions in the service
manual.

20 〜 25N・m(2.0 〜 2.5kgf・m)

Adjust bolt

Lock nut

Adjusting nut○ Install release arm with faced gap back, then hockthe spring to the arm and case while fully pull thearm.

Removal direction

Flange bolt
Clutch release arm
Caution : Be sure to follow the specified torque.
Torque:20 〜 25N・m (2.0 〜 2.5kgf・m)‑B1‑Aug./12/ 13

CO○Attach the flange bolt to the release arm, and tighten
the bolt to the specified torque, pressing the arm.
Caution : Be sure to follow the specified torque.
Torque: 10 N･m (1.0 kgf･m)○ Adjust the free play at the clutch with the adjusteron the clutch cable, then tighten the locking nuts tothe specified torque, and cover the clutch cableadjusters at both ends with rubber caps.

Caution : Be sure to follow the specified torque.
Torque: 10 N･m (1.0 kgf･m)

Adjust bolt

●Installation of carburetor:☆ In the case of PE28:○Route the supplied throttle cable along the frame justlike the stock throttle cable was routed.
○ Pass the throttle cable through the lower throttle
housing, and connect the inner cable to the throttle
pipe.

Fits only the Monkey∴NOT installable onto the Gorilla

And attach the throttle housing to the steering handle.
※ Apply grease to the rubbing surface of the throttle
pipe, cable end and the cable taking-up portion on thepipe.
○ Put a inlet pipe gasket between the cylinder head
and the inlet pipe, and tighten it with 6x20 socket cap
screw to the specified torque.

○Remove a float chamber, and then a main jet. Attacha supplied main jet #110 and slow jet #35, and then afloat chamber.
○Detach a top cover of the supplied carburetor, andpull out the spring and throttle valve.
Pass the inner cable of the throttle cable through the
carburetor top cover and then through the spring.
And compressing the spring, fix the top cover and allto the throttle valve. Fix the throttle valve to the
carburetor by aligning a notch on the throttle valve
with the throttle stop screw.

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Caution : Be sure to follow the specified torque.
Torque: 10 N･m (1.0 kgf･m)

Lock nut

Adjusting nut

Clutch free play :10 to 20 mm at the clutch lever end
10 to 20 mm

Clutch lever○ Insert the carburetor into the insulator, and fasten
them with a clamp band.

Caution : Be sure to follow the specified torque.
Torque: 10 N･m (1.0 kgf･m)○With the engine turned off, shift the transmission to
the first gear. Then, check that the rear wheel
rotates when you move the machine, squeezing
the clutch lever, and that the rear wheel does not
rotate when you have released the clutch lever.

Less free playMore free play
Adjuster
About 5 mmScrew 6X20

○ Fasten the carburetor insulator, to be used on theinlet pipe, with the supplied two socket cap screws.

●Inspection:○ Attach an air filter, which please secure bytightening a band.
○ Adjust the free play at the throttle grip to be about
5 mm by turning the adjuster of the throttle cable.
☆ Follow the instructions of your throttle cable toadjust the free play.

‑B2‑

Snap the throttle a few times to make sure that thethrottle moves smoothly without sticking and thatthe throttle valve is fully open. And check that thethrottle has free play even when a steering handle
is turned all the way to the right or to the left.
○Insert a fuel tube and fasten it with a tube clip.
Open the fuel cock and check for oil leaks.

Aug./12/ 13

☆In the case of VM26:

CO○Remove the top cover from the carburetor, and pullout the spring and the throttle valve.
Pass the inner cable of the throttle cable throughthe carburetor top cover and then through thespring. And compressing the spring, fix the top
cover and all to the throttle valve. Fix the throttle
valve to the carburetor by aligning a notch on thethrottle valve with the throttle stop screw.

○ Adjust the free play at the throttle grip to be about
5 mm by turning the adjuster of the throttle cable.
☆ Follow the instructions of your throttle cable to adjust
the free play.

○ Dispose of the blow-by gas from the crankcase by
yourself.
(Some races and regulations stipulate the blow-by
gas disposal.)○In sending back the blow-by gas to the carburetor,
connect the blow-by hose with the union on the
air-filter.

●Engine oil○ Remove the cap and add 850cc of engine oil.

Oil Inlet Cap(See Optional parts chart on P-D1)

Less free playMore free play

Adjuster

About 5 mm

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○ Referring to the chart below, choose the engine oil
whose viscosity matches the region and outside
temperature.

Snap the throttle a few times to make sure that thethrottle moves smoothly without sticking and that thethrottle valve is fully open. And check that the throttle
has free play even when a steering handle is turned
all the way to the right or to the left.

○ Insert the carburetor into the insulator, and fasten
them with a clamp band.

※ In the case of installation to any model of the Gorilla,
replace the pre-installed fuel cock with the suppliedcock. Adjust the direction of the fuel cock and fasten
the nut to the fuel tank.
Caution : Be sure to follow the specified torque.
Torque: 5 〜 6N･m (0.5 〜 0.6 kgf･m)○Install the oil inlet cap.
○Install an optional kick starter arm.
Caution : Be sure to follow the specified torque.

○ Attach an air filter, which please secure bytightening a band.
○ Insert a fuel tube and fasten it with a tube clip. Openthe fuel cock and check for oil leaks.
(Do not leave the cock open for many hours.)‑B3‑Aug./12/ 13

●Installation of drive chain○ Remove generator cover.(3 bolt)

CO○ Apply “Alumi-special” paste on the top of the
crankshaft (where goes to bearing on the cover) andinstall generator cover.
Caution : Be sure to follow the specified torque.
Torque: 10 N･m (1.0 kgf･m)○ Install the drive sprocket.

Caution : Be sure to follow the specified torque.
Torque: 12 〜 15N･m (1.2 〜 1.5 kgf･m)

Sprocket

AL‑SPL

Plate

Plate
Bolt

Chain

○ Install the drive chain referring to a genuine
service manual or instruction manual for the
relative rear fork.
Warning : Do follow the instructions in the service
manual.

○ Install the change pedal.

○ Check that the ignition key and gas cock are turned
off.
○Keep kicking the starter for a while till the engine oil
circulates all around the engine.
○ Install the spark plug. Lightly apply the “AluminumSpecial”, the heat-resistant lubricating agent, to thethreaded portion on the plug. And tighten the plug.
Caution : Be sure to follow the specified torque.
Torque: 8 〜 10 N･m (0.8 〜 1.0 kgf･m)

PY○ Attach the plug cap to the spark plug.
○ Thoroughly wipe off dirt and dust on the engine.
○ Turn on the gasoline cock and the ignition key.
Pull a choke lever to start the engine.
Gradually loosen your grip on the lever, and warm up

Caution : Be sure to follow the specified torque.

● Install the exhaust system● Start engine○Attach a supplied exhaust pipe gasket to the exhaust
port.

Chain clip

the engine till the revolution becomes smooth.
And then return the lever fully back to its original
location.
If the engine does not run idle after warming-up, or itruns idle at high revolutions, adjust the revolutions
with the throttle stop screw.

○ Stop the engine once.
Wait for a few minutes and keep the motorcycle
level to the ground, and then check the oil amountwith oil level gauge on right crankcase.

Upper
limit
Oil site window

Lower
limit

∴ Always keep the oil to the specified level.
(Use the same grade and brand oil.)○ Check for malfunctions such as unusual sounds.
○ If no malfunction is detected, do the setting of the
carburetor.
(See the attached sheet)
Warning : Be sure to do the work in a wellventilated place.
○ Carry out again a shakedown up to about 50 to
100 km.
○ After the shakedown, check for malfunctions suchas unusual noises or blow-by gas.
(If there is any malfunction, disassemble the engine
again to check each part.)
Caution : Never reuse parts which are notsuitable for reuse.
Warning: Those who are technically unskilled or
inexperienced are required not to do
the work.

In the direction of thechain’s movement○ Install the change pedal.
Caution : Be sure to follow the specified torque.
○Install an exhaust muffler according to the installation
instructions of the relative exhaust muffler.
‑B4‑Aug./12/ 13

CO◎ About Optional Clutch Parts:● In the case of not installing the thermo unit

(Installation of thermo unit)

１．Detach the thermostat hole cap, and fit an oil hole

After removing a thermostat hole cap, install thethermo unit.
※For details, see the Instruction Manual for thethermo unit.
※ The thermo unit alone does not function.

（Oil Cooler Installation）● In case a thermo unit is to be installed:

１．Install a thermo unit.
２．Unfasten two oil plug bolts, and install an adapter

suitable for the kind of hose you will use. Thenconnect the hose.
※Please see the instruction manual for the thermo
unit.
※ Please see the instruction manuals for the oilcooler kit and the adapter.

Rubber hose

Slim-line hose

Allegri’s hoseplug (option) into the oil hole.
２．Apply engine oil to the O-rings of the thermostat
hole cap, and tighten the hole cap to thespecified torque.

possibility that the○φ 30 Upright Front Fork
оClamp the top bridge at the highest point of thestraight portion to avoid the tapered portion offront fork.
※ Before installing, make sure that nointerference occurs when the front fork is fully
bottomed.

engine is damaged

３．Unfasten two oil plug bolts, and fit an adaptor tomatch the hose to be used. And connect the hose.
※ For details, see the Instruction Manuals for an Oil
Cooler Kit and an Adaptor.

Thermostat hole cap

NEVER install a thermo unit or an oil hole plug. And incase the thermo unit and / or an oil hole plug isinstalled, DO be sure to remove it or them.

Caution：There is a

Caution : Be sure to follow the specified torque.
Torque: 13 N・m (1.3 kgf・m)

because the oil

Tapered portion

passage will be

PYblocked when thethermo unit or an oilhole plug is installed.

Oil hole plug

Caution：NEVER install athermo unit or an oilhole plug if you do
not connect an oil
hose to the clutch
cover.
There is apossibility that theIn case an oil cooler is not installed: ◎Relevance of Front Fork and TireＩＮ ＯＵＴ

engine is damaged
due to the oil
passage blockage.
‑B5‑

Aug./12/ 13

COGenerator side
黄1
Yellow 1
黄2
Yellow 2
緑
Green
青/黄
Blue/Yellow
黒/赤Black/Red
若葉/赤 Light Green/Red

Bike side
黄Yellow
白
White
緑
Green
青/黄
Blue/Yellow
黒/赤Black/Red
若葉/赤 Light Green/Red

Engine Stop Switch

Function機能
灯火用AC出力（AC電源用） Lighting AC output (for AC power)
灯火用AC出力（DC電源用） Lighting AC output (for DC power)
Main GND
メインアース（GND）
パルスジェネレーター信号 PIckup pulse
点火用AC出力
Ignition AC output
ニュートラルスイッチコード Neutral Switch

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TAKEGAWA C.D.I.

Black/White

Ignition CoilBlack/Yellow

Black/Red

Blue/Yellow GreenBlack/RedBlue/Yellow

Yellow 1

GreenA
fo C G
r en
Sp er
ar at
k or
AC
fo G
r en
Li er
gh at
ti or
ng
Ti
Ge mi
ne ng
ra P
to ul
r se

Yellow 2

Racing use[Yellow 1][Yello 2][Light Green/Red]※ Wires
are unconnected.

Light Green/RedN
Sw eutit ra
ch l

ON:STOP

GreenSuper Street
outer rotor kit‑B6‑Aug./12/ 13

CO〜 Inspections and Adjustments 〜

CAUTIONBe sure to use a torque wrench and strictly keep the specified torque.

WARNING

The inspections and adjustments are intended for use by qualified professional mechanics. Be sure that any person who does not have the proper
technique, experiences and knowledge will never work.

●Spark plug:○ Check if the electrode section is worn out, corroded
or burnt-out, or its insulator is damaged.
When necessary, change the spark plug.
○ With a wire brush or a plug cleaner, clear the plug
electrode section of the accumulated residues.
○ Check the plug gap with a thickness gauge.
And when the gap deviates from the benchmark,adjust it by bending the electrode section.

Standard
・ NGK: ER8EH○Detach a plug cap, and then a spark plug with a●Oil Change:○ Warm up the engine within a few minutes to normal
operating temperature.
○ Prepare an oil container under the drain bolt.
And drain the oil while the engine is warm.

PY

plug wrench.

○ Apply a small amount of ALUMI SPECIAL on screwsof spark plug. Tighten the spark plug and install the

And when the gap deviates from the benchmark,adjust it by bending the electrode section.

Caution : Be sure to follow the specified torque.

plug cap.

○ Install the drain bolt, and tighten it to the specified
torque.
Caution : Be sure to follow the specified torque.
Torque: 19.5 〜 24.5 N・m(2.0 〜 2.5 kgf・m)○ Remove the cap of oil inlet and add 750cc of engine
oil.

Oil Inlet Cap

ElectrodesectionRelationship between
temperatures and viscosity

Plug with high thermal value (Cold type)・ NGK: ER9EH○ With a wire brush or a plug cleaner, clear the plug
electrode section of the accumulated residues.
○ Check the plug gap with a thickness gauge.

Gap○ Add the engine oil in the specified amount.
∴ Recommended oil:
SAE 10W - 40 20W - 50
API class, SF grade engine oil∴ Oil amount:
When oil change ONLY :750cc
When rebuilt the engine :800cc○ Referring to the chart below, choose the engine oil
whose viscosity matches the region and outside
temperature.

Outsidetemperatures○Install the oil inlet cap.
○Warm up the engine within a few minutes to normal
operating temperature.
○ Stop the engine once. Wait for a few minutes andkeep the motorcycle level to the ground, and thencheck the oil amount with oil level gauge on rightcrankcase.

Upper limit

Lower
limit

∴ Gap
Benchmark : 0.6〜0.7 mm

Oil site window∴ Always keep the oil to the specified level.
(Use the same grade and brand oil.)‑C1‑

Oct./11/ 11

● Change of Oil filters:

CO○ Unfasten two bolts on the oil filter cover, anddetach the oil filter cover, oil filter and oil filter spring.

○ Apply a thin coat of engine oil to the O-ring on the oil
filter cover, attach an oil filter and oil filter cover, andtighten two bolts to the specified torque.

●Adjust the Clutch Cable○ Inspect the free play of clutch lever.
10 to 20 mm

Clutch lever

Caution : Be sure to follow the specified torque.
Torque: 10 N・m(1.0 kgf・m)
Oil filter spring○ Check the O-ring in an oil filter cover, and change
it when necessary.
○ Attach a new oil filter to the filter cover.
Filter cover○ Turn the adjust nut of clutch holder and adjust thefree play of clutch lever.

PY
Lock nut

Adjust nut○If you cannot adjust the free play with the lever holder,adjust it with the adjust nut of receiver.

Oil filter
00-02-0027

O-ring00-02-0040○ Place the oil filter spring at the protrusion on theright side crankcase cover.

Cable receiver

Adjust bolt

Lock nut

Adjust nut○Tighten the lock nuts on clutch lever and clutch cablerespectively.
Caution : Be sure to follow the specified torque.
Torque: 10 N･m (1.0 kgf･m)‑C2‑

Oct./11/ 11

COHow to Set the Carburetor

・When the carburetor does not match the engine and the engine fails, the engine failures are caused by either too dense or too lean air-fuel mixture.
・The engine failure symptoms for the engine are as follows:

When the air-fuel mixture is too dense:

When the air-fuel mixture is too lean:

・The explosion sound with a dull thud continues intermittently.
・The engine malfunctions further if you use the choke.
・The engine malfunctions when you warm it up.

・The engine overheats somewhat.
・The engine starts working well If you use the choke,.
・The engine does not accelerate well. (No smooth acceleration)

・The engine works well if the cleaner is detached.
・The motorcycle belches dense (or, black) exhaust gas.
・The plug smolders, getting blackened.

・Revolutions change, generating weak power.
・The plug burns white.

PY※ Set the carburetor only after warming up the engine, and then test-drive. And use a plug with the right heat value.
※ Do the setting in the following manner, studying at what throttle opening position the engine starts failing.

○Jet needle (Throttle position at 1/4 - 3/4)

○ Air screw

Whether or not the engine revolution is in proportion to the throttle operation
・When the acceleration is not smooth or even, make the air-fuel mixture dense.
・Make the air-fuel mixture lean when the engine revolution goes up heavily and belches black gas.
The mixture ratio at this throttle position can be adjusted by the location of E-ring in the grooves.
The air-fuel mixture becomes dense as the location of the E-ring moves down from the 1st to the 5th groove.

2段目
2nd groove
1段目
1stgroove

3rd groove
4段目
4th
groove

5段目
5thgroove

The air screw adjusts the air mass flow at the time of engine’s revolving at slow speed. (At idling)
・Give the air screw a right turn → The air-fuel mixture gets dense.
・Give the air screw a left turn → The air-fuel mixture gets lean.
Loosen the tightened air screw back to the 1.5-turn position. And then from this position, give to the airscrew
a right or left turn of 1/4 to 1/2 till the engine revolves at the highest speed.
Loosen the idle stop screw till you get the steady idling revolutions. And once again adjust the position of the
airscrew to get the highest revolutions.

●On how the barometric pressure, temperatures and humidity affect the setting:○Main jet (The throttle position at 3/4 - 4/4)

・At highlands or at high altitudes, the barometric pressure and air density go down and the air gets into the
carburetor in less amounts.
This makes the air-fuel mixture dense which was adjusted at low altitudes.
・Under the weather conditions with very low temperatures, the air density increases, which makes the
air-fuel mixture lean.
・Under the rainy and humid weather conditions, the air density decreases, which makes the air-fuel mixture
dense.

The air-fuel mixture ratio at this throttle position can be adjusted by changing the number of the main jet.
The larger the main jet numbers, the denser the mixture ratio becomes.
In view of the engine and muffler specifications, select the most appropriate main jet to get the highest
revolutions.

○Pilot jet (First of all, please adjust the air screw.)・In case you have given more than three turns to the air screw to tighten it, use a pilot jet with a small number.
・If you have tighten the air screw (clockwise) to the full, use a pilot jet with a larger number.
Check whether you have made a right choice of the pilot jet by seeing if the engine starts up revolving smoothly from the idling to running at slow speed.
・When the engine revolves up unevenly, the pilot jet number is too small. (At idle)
・ When the motorcycle belches black exhaust gas and produces heavy exhaust sound, the pilot jet number
is too big. (At idle)
・After replacing the pilot jet, you need to readjust the airscrew.

◎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.

‑C3‑

Oct./11/ 11

VM26 Carburetor
Item Nos
00-03-0151
00-03-0152
00-03-0153
00-03-0154
00-03-0155
00-03-0156
00-03-0157
00-03-0158
00-03-0159

COPE28 Carburetor

Product Names
Pilot jet, # 10
Pilot jet, # 12.5
Pilot jet, # 15
Pilot jet, # 17.5
Pilot jet, # 20
Pilot jet, # 22.5
Pilot jet, # 25
Pilot jet, # 27.5
Pilot jet, # 30

03-03-0321

Item Nos
00-03-0060
00-03-0061
00-03-0062
00-03-0063
00-03-0064
00-03-0065
00-03-0066
00-03-0067
00-03-0068
00-03-0069
00-03-0070
00-03-0071
00-03-0072
00-03-0073
00-03-0074
00-03-0075
00-03-0076
00-03-0077
00-03-0078
00-03-0079
00-03-0080
00-03-0081
00-03-0082
00-03-0083
00-03-0084
00-03-0085
00-03-0086

Product Names
Main jet, # 100
Main jet, # 105
Main jet, # 110
Main jet, # 115
Main jet, # 120
Main jet, # 125
Main jet, # 130
Main jet, # 135
Main jet, # 140
Main jet, # 145
Main jet, # 150
Main jet, # 155
Main jet, # 160
Main jet, # 165
Main jet, # 170
Main jet, # 175
Main jet, # 180
Main jet, # 185
Main jet, # 190
Main jet, ♯195
Main jet, ♯200
Main jet, ♯210
Main jet, ♯220
Main jet, ♯230
Main jet, ♯240
Main jet, ♯250
Main jet, ♯260

Item Nos
00-03-0137
00-03-0138
00-03-0139
00-03-0140
00-03-0141
00-03-0142
00-03-0143
00-03-0144
00-03-0145
00-03-0146
00-03-0147
00-03-0148
00-03-0149
00-03-0150

Product Names
Slow jet, ♯35
Slow jet, ♯38
Slow jet, ♯40
Slow jet, ♯42
Slow jet, ♯45
Slow jet, ♯48
Slow jet, ♯50
Slow jet, ♯52
Slow jet, ♯55
Slow jet, ♯58
Slow jet, ♯60
Slow jet, ♯62
Slow jet, ♯65
Slow jet, ♯70

03-03-027

Involute throttle set

Insulator
for VM26

for PE28

58 mm

58 mm

φ 34

φ 35

Outer length: 710 mm

Product Names
Main jet, #82
Main jet, #85
Main jet, #88
Main jet, #90
Main jet, #92
Main jet, #95
Main jet, #98
Main jet, #100
Main jet, #102
Main jet, #105
Main jet, #108
Main jet, #110
Main jet, #112
Main jet, #115
Main jet, #118
Main jet, #120
Main jet, #122
Main jet, #125
Main jet, #128
Main jet, #130
Main jet, #132
Main jet, #135
Main jet, #138
Main jet, #140

Item Nos
00-03-0107
00-03-0108
00-03-0109
00-03-0110
00-03-0111
00-03-0112
00-03-0113
00-03-0114
00-03-0115
00-03-0116
00-03-0117
00-03-0118
00-03-0119
00-03-0120
00-03-0121
00-03-0122
00-03-0202
00-03-0123
00-03-0124
00-03-0125
00-03-0126
00-03-0127
00-03-0128
00-03-0129

Product Names
Main jet, #142
Main jet, #145
Main jet, #148
Main jet, #150
Main jet, #152
Main jet, #155
Main jet, #158
Main jet, #160
Main jet, #162
Main jet, #165
Main jet, #168
Main jet, #170
Main jet, #172
Main jet, #175
Main jet, #178
Main jet, #180
Main jet, #182
Main jet, #185
Main jet, #188
Main jet, #190
Main jet, #192
Main jet, #195
Main jet, #198
Main jet, #200

PY

Standard high throttle set

09-02-0222 (710 mm in outer length)09-02-0221 (810 mm in outer length)09-02-0230 (Black anodized)
09-02-0232 (Gray metallic anodized)
30 mm

30 mm

High flow filter
Item Nos
00-03-0130
00-03-0131
00-03-0132
00-03-0133
00-03-0134
00-03-0135
00-03-0136
00-03-0090
00-03-0091
00-03-0092
00-03-0093
00-03-0094
00-03-0095
00-03-0096
00-03-0097
00-03-0098
00-03-0099
00-03-0100
00-03-0101
00-03-0102
00-03-0103
00-03-0104
00-03-0105
00-03-0106

Shape-maintaining
stainless spring
Pebblesand sandAir
Air
Pebblesand sandHigh flow filter

03-01-1064

for MIKUNI VM26

03-01-1094

for KEIHIN PE28

Fuel cock assembly

03-03-001

90-bent high throttle set

09-02-021 (700 mm in outer length)

Outer length: 810 mm
09-02-0231 (Black anodized)
09-02-0233 (Gray metallic anodized)

φ 2900-03-0210

φ 29

For more information, please refer to our parts catalog, or log onto our Web site at
URL http://www.takegawa.co.jp

00-03-0211‑D1‑Aug./12/ 13

Racing C.D.I. Magnet Kit

CO05-02-0511○ Excellent startup performance because of ignition at low
revolution. (Excellent start-up by a kick starter)○Ignition timing adjustable at up to 24 degrees,○Integral ignition coil with built-in CDI unit,○Fully-covered stator coil to protect the ignition coil,○Weight saving:R-type φ58 rotor: 336 g

Stator, including cords: 383 g
Ignition coil, including cords: 370 g○ “ROSSA” (red) as proof of high performance※No charging functions

Kick starter arm(Steel-forged)

Clutch lever assembly(Aluminum-forged)

02-01-028(black)02-01-0282 (silver)

09-10-006(Back step should not be installed.)

02-08-0052

Steel Drive Sprocket

02-05-041 (15T Racing)

02-05-02 (13T Standard)
02-05-03 (14T Standard)

02-05-051 (16T Racing)Gear Ratio (Final)
Driven

12T
13T
14T
15T
16T

PY
02-01-0601

Steel Driven Sprocket

Aluminum Driven Sprocket

02-05-01 (12T Standard)

Drive

Quick lever ASSY.

23T

24T

25T

26T

27T

28T

29T

30T

1.91
1.76
1.64
1.53
1.43

2.00
1.84
1.71
1.60
1.50

2.08
1.92
1.79
1.67
1.56

2.17
2.00
1.86
1.73
1.62

2.25
2.08
1.93
1.80
1.68

2.33
2.15
2.00
1.87
1.75

2.42
2.23
2.07
1.93
1.81

2.50
2.31
2.14
2.00
1.87

02-07-0641 (41T)
02-07-0642 (42T)

02-07-0011 (25T)
02-07-0012 (28T)

02-07-0007 (23T)
02-07-0008 (25T)

02-07-0643 (43T)

02-07-0013 (30T)
02-07-0014 (33T)

02-07-0009 (28T)
02-07-0010 (23T)

31T

32T

33T

34T

35T

36T

2.58
2.38
2.21
2.07
1.93

2.67
2.46
2.29
2.13
2.00

2.75
2.54
2.36
2.20
2.06

2.83
2.62
2.43
2.27
2.12

2.92
2.69
2.50
2.33
2.18

3.00
2.77
2.57
2.40
2.25

For more information, please refer to our parts catalog, or log onto our Web site at
URL http://www.takegawa.co.jp‑D2‑Aug./12/ 13

COCompact cool

The oil “Compact Cool” is designed more compact compared to our current oil cooler and the best for mini motorcycles such as Monkey / Gorilla. The oil passage is
our Standard Type and the corrugated louver fins are incorporated. This cooler body has an oil cooler plate and guard as standard equipments. In addition, the bracket
mounting is integrated with the oil cooler plate so that you can use the oil outlet upside down as well.

3-Fin 4-Line AW
00-07-0055

Oil cooler

4-Fin 5-Line AW
00-07-0008

Compact coolMounting Position

Steering Stem mount

OutletClutch cover

3Fin
4Line

4Fin
5Line

Rubber hose

07-07-0125

07-07-0126

Slimline hose

07-07-0123

07-07-0124

Thermostat
Only for wet-type clutch cover

PY

Unusually quick response to temperature change is realized through the use of shape-memory alloy.

A relief passage can be secured via bias spring even when the oil pressure has increased because of the clogged oil cooler.
At the time of low oil temperatures, oil does not flow out to the oil cooler because the thermo unit valve closes, but it flows back to the filter

through the bypass passage. When the oil temperatures rises to more than 70 degrees, the valve opens to let the oil flow to the oil cooler.

02-01-5052 Thus, the thermo unit serves to prevent the overcooling and to keep the oil at a fixed temperature.

For more information, please refer to our parts catalog, or log onto our Web site at
URL http://www.takegawa.co.jp‑D3‑Aug./12/ 13

Oil catch tank(cylinder type)CO(side cover type)07-05-0010

09-04-032

Tank capacity : 420 cc

Front fork

Tank capacity : 550 cc

Rear fork

PY

06-01-0732
φ 30 Front Fork Set w/Disc brake(For 10-inch ONLY)

06-03-0116 Aluminum Swingarm (12cm-extended)
06-03-0114 Aluminum Swingarm (16cm-extended)

Our original front fork with φ30 inner tube increases the stability ofstroke by damping force generating mechanism of “free-valve” type

Both high rigidity and lightweight, which are both essential for swingarm, have beenand reduces the shock when the front shocks rebound and compress.

06-03-0115

Aluminum Swingarm (16cm-extended) w / Stabilizer

achieved with the well-balanced structure of our original polygon sectional design andthickness of the material.
Moreover, skillful bending and buff finish are excellent and appeal more than others.

06-02-0015
Top Bridge & Stem

06-01-0723
L / R Front Fork Set

For more information, please refer to our parts catalog, or log onto our Web site at
URL http://www.takegawa.co.jp‑D4‑Aug./12/ 13