D-Style Muffler Instruction Manual

COItem No.
：０４−０２−０４３１
Applicable to ：DAX 50 (12V)
Frame No.

：AB26-1000001 〜

Thank you for purchasing one of our TAKEGAWA’s products. Please strictly follow the following instructions in installing and using the products. Before
fitting the products, please be sure to check the contents of the kit. Should you have any questions about the products, please kindly contact your dealer.
Before installation, please read this instruction manual carefully and understand the instructions fully.
Enjoy the sound and performance of this muffler distinct from a stock muffler.
◎ Please note that, in some cases, the illustrations and photos may vary from the actual hardware.

〜 Features 〜

PY○ This is a genuine-like up-muffler for the DAX 50, to which a genuine muffler guard can be installed.
It improves the performance without altering the original look of the DAX 50.
○ We have adopted a silencer body and exhaust pipe, both made of stainless, to improve the appearance and durability.

Please read the following instructions before installation.

◎ The following show the envisioned possibility of injuries and damages to human bodies, and physical loss or damage as a result of disregarding thefollowing cautions.
◎ 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 product is designed for exclusive use in the above-mentioned types of motorcycles and frame numbers only. Please take note that this productcannot be mounted on other types of motorcycles.
◎ Please refrain from combined use of this kit with any other part than the specified parts.
◎This product is designed for exclusive use in a stock kick starter arm. (In case of TAKEGAWA’s kick starter arm, the arm will interfere with the genuinemuffler guard.)◎ This product should be used with a stock muffler protector. Or, no-installation of the protector may cause scalding. So, be sure to install the muffler
protector.
◎This product is designed for absolute use with a genuine rear shock absorber. If other rear shock absorber is installed, please install this product withwashers so the rear shock absorber and the muffler do not interfere with each other.

CAUTION

The following show the envisioned possibility of injuries and damages to human bodies, and property loss as a result ofdisregarding the following cautions.

・Always try to drive your motorcycle at a legal speed, abiding by the laws.
・Work only when the engine and the muffler are cool. (Otherwise, you will burn yourself.)
・Prepare right tools for the work, and do the work in the proper and right way.
(Otherwise, improper work could cause breakage of parts or injuries to yourself.)
・Always use a torque wrench to screw bolts and nuts tight and securely to the specified torque.
(Improper torque could cause these parts to get damaged or fall off.)・As some products and frames have sharp-pointed or protruding portions, please work with your hands protected.
(Otherwise, you will suffer injuries.)
・Do water washing of a muffler only when it is cool. (Otherwise, the muffler may be cracked.)・Park your mortorcycle in a place where pedestrians will not touch the muffler accidentally. Besides, please always be considerate enough notto park it in the way of pedestrians or moving vehicles.
(If you park your motorcycle on the sidewalk with its muffler on the pedestrians’ side, the pedestrians may touch the muffler and get burned orsuffer property loss.)・Before riding, always check every section for slack in parts like screws. If you find slack ones, screw them securely up to the specified torque.
(Or improper torque may cause parts to come off.)
・This muffler is designed for exclusive use in a stock kick starter arm. TAKEGAWA’s kick starter arm will interfere with the genuine muffler guard.

‑1‑Oct./07/ 08

WARNING

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

・Always drive the engine in a well-ventilated place, and do not switch the engine on in an airtight place.
(Otherwise, you will suffer from carbon monoxide poisoning.)
・Never look into the muffler outlet when the engine is revolving. (Otherwise, you will suffer from carbon monoxide posoning or lose your sight.)
・When you notice something abnormal with your motorcycle while riding down a road, stop riding immediately and park your motorcyle in asafe place. (Otherwise, the abnormaility could lead to an accident.)
・Before riding, be sure to always check the bank angle, and run with care not to bank the vehicle more steeply than the bank angle.
(Otherwise, there will be a danger of the motorcycle overturning.)
・The engine and the muffler are at high temperatures when the engine is revolving or for some time after the engine stopped. Therefore, neverplace flammable or hazardous materials such as gasoline near them. (Otherwise, there will be a danger of causing fires.)・Before doing work, place the motorcycle on level ground to stablize the position of your motorcycle for safety's sake.
(Otherwise, your motorcycle could overturn and injure you while you are working.)
・Check or perform maintenance of parts correctly according to the procedures in the instruction manual or a service manual.

CO(Improper checking or maintence could lead to an accident.)
・If you find damaged parts when checking and performing maintenance, 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 an accident.)
・Keep plastic bags for packing products out of children’s reach, or discard them.
(If children get them on, there will be a danger of their suffocating. )・Basically, you can install this muffler in almost the same way as installing a stock muffler. Although a genuine muffler can be fixed, a guard foran exhaust pipe (right behind the engine exhaust) cannot be installed. So, please do be careful not to let your right leg touch the exhaust pipe
when pressing down on the rear brake pedal.

PYBesides, do not ride the vehicle in an exposed style, such as in sandals. (It could lead to burn or accidents.)◎ 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.
◎ You are kindly requested not to contact us about the combination of our products with other manufacturers'.
◎ You are requested to keep this instruction manual until you discard this product.

〜 Kit Contents 〜

２１３ ４No.
1234
5
6
7Parts Name
Silencer assembly
Exhaust pipe COMP.
Pivot nut
Flange bolt, 8 x 16
Exhaust gasket
Protector gasket
Exhaust pipe flange

Qty
111
1
1
2
1Repair Part Item No.

04-00-014
BW-00-0109
000-13-016
04-00-026
18352-181-T00

７５

６In packs of

1
4
1
5
1

∴Please order repair parts by indicating the Repair Part Item No. as listed above.
As you see from the list, there are some parts for which we are not in a position to accept your order in the quantity of one.
In this case, please order the required parts as a set part unit.
‑2‑Oct./07/ 08

〜 Installation Procedures 〜
Stabilize the vehicle with a maintenance stand or the like in a safe and level place during work.

●Stock Muffler Removal●Stock Muffler Guard Removal●D-Style Muffler Installation

１．
Unfasten two nuts on the exhaust pipe flange.

１．Remove the screws and bolts from the just-

１．Insert and install a kit’s exhaust pipe gasket

COKeep them for re-use.
If the nuts are worn or damaged severely,replace them with new ones.

now-removed stock muffler, as shown byarrows in the below-mentioned photo, toremove the muffler guard.
２．Remove all the plus screws holding the muffler
and muffler guard.
Retain the screws and protector band packing
for reuse. The screw and hole indicated by anarrow A will not be used.

to the exhaust port.

And in case the screws are badly damaged,please prepare new ones separately.

２．Remove two hex bolts which are holding themuffler.

２．
Fix a pivot nut onto the upper part of theright-side rear shock absorber.
Torque : 35 N・m (3.5 kgf・m)

ＡPY

CAUTION: Plus screws may be very tightly
screwed, so unscrew them withenough care not to damage theirheads.

３．In case the protector band packing is badly
damaged, please prepare new one separately.

３．Remove the old exhaust pipe gasket
remaining in the exhaust port.

３．Install for now the silencer assembly with asupplied flange bolt.

４．After inserting the exhaust pipe into the joint
on the silencer assembly, insert its flange
into the engine.
※ It is advisable to apply heat-resistant liquidgasket to the inserting portion.
(ThreeBond 1207B or the equivalent.)‑3‑Oct./07/ 08

５．Install the exhaust pipe flange onto theexhaust pipe COMP.
Pass the installed exhaust pipe flange throughthe stud bolt of the cylinder head, and fix theflange with the nuts which were used to fix
the stock muffler, and install the pipe for now.
Install the exhaust pipe flange onto theexhaust pipe COMP. , directing its edged andlusterless surface to the cylinder head.

８．Install the stock muffler guard. The stock plus
screw will be reused. Place the supplied
protector gaskets between silencer andmuffler guard, and tighten the screw.
As this screw is apt to come off from thevibrations of the vehicle, it is advisable to apply
screw locking agent to it like a Lock tight 241, orthe equivalent. Fix the front part of the muffler
guard to the muffler by installing the protector

COband packing.
Flange bolt
Torque : 10 N・m (1.0 kgf・m)● Final Checking
１．Start the engine in a safe and well-ventilated
place, and check for exhaust leak orintereference.
WARNING : Otherwise, you will suffer fromcarbon monoxide poisoning.
２．After stopping the engine and after each parthas cooled down to the normal temperatures,
re-tighten all screws and nuts to thespecified torque.

Protector gasket

６．Tighten the exhaust pipe flange nuts evenly
to the specified torque with care not to let thesilencer and the exhaust pipe get out of theadjusted places.
Torque : 10 〜 12 N・m(1.0 〜 1.2 kgf・m)

PY(Stock) protector band packing

Flange bolt

７．Next, tighten the flange bolt on thesilencer stay to the specified torque.
Torque : 27 N・m (2.7 kgf・m)

９．Check for intereference among the muffler
guard, the muffler, and the frame. If need be,loosen the screws and nuts on each section toadjust the positions to the extent that theadjusting does not place too much strain on themuffler. Then fix them.

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‑Oct./07/ 08