Instruction Manual for 4-Stroke DIO (AF62) Bar Handle Full Kit

COItem No.

：０６―０２―０３０１

Fits

：Dio

Frame Nos ：AF62-1000001 〜・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.

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 kit not in conformity with the instructions in the
manual.
◎ We shall be held free from any responsibility or compensation whatsoever for any glitch in the parts other than ours if the glitch takes place after the
installation and use of the products.
◎ If you make modifications to any product of the kit, we shall be held free from any guarantee of the product.
◎ You are requested not to contact us about the combination of our products with other manufacturers'.
◎Please note that this kit is designed for exclusive use in the above-mentioned fitting models and frame numbers only and that it cannot be mounted on
any other models.

PY

About the bar handle kit◎ Installation of this kit requires some wire processing.

◎ Installation of turn signals requires boring of a front cover.
◎ In order to build a bar handle using this kit, please separately purchase the following TAKEGAWA-made parts and HONDA-made genuine parts.
◎As a stock meter assembly is to be removed, a fuel meter becomes unavailable. If you need the meter, please purchase an extra-cost TAKEGAWAmade Fuel Meter Kit of Item No.09-01-2010, or Compat LCD Fuel Meter Kit of Item No. 07-04-0019.
◎ In case you use other steering handle and headlight than those included in this kit, please use them on your own responsibility.
Honda’s genuine parts:
For use in Today
Switch set, turn signal (part #: 35020-GFC-890) 1 piece
Socket COMP., headlight (33130-GFC-890)
1 piece

The following show the envisioned possibility of injuries to human bodies and property damage as a result of disregarding the
CAUTION following cautions.
・Always try to drive your motorcycle at a legal speed, abiding by the laws.
・Work only when the engine and muffler are cool. (Otherwise, you will get burned.)
・Do the installation with right tools. (Otherwise, breakage of parts or injuries to you may take place.)
・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.)

・As some products and frames have sharp edges or protruding portions, please work with your hands protected.
(Otherwise, you will suffer injuries.)
・Before riding, always check every hardware like screws for slack. If you find slack one, screw them securely up to the specified torque.
(Otherwise, improper tightening may cause parts to come off.)

WARNING

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

・When you notice something abnormal with your motorcycle while riding, immediately stop riding and park your motorcyle in a safe place tocheck what has gone wrong. (Otherwise, the abnormality could lead to accidents.)
・Before doing work, make sure your motorcycle is secure on level ground for safety's sake.
(Otherwise, your motorcycle could overturn and injure you while you are working.)
・Check or carry out maintenance of your motorcycle correctly according to the procedures in the instruction manual or service manual.
(Improper checking or maintenance could lead to accidents.)
・If you find damaged parts when checking and performing maintenance of your motorcycle, do not use these parts any longer, and replacethem with new ones. The continued use of these damaged parts as they are could lead to 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.
‑1‑

Jan./09/ 07

Kit includes:
２

１

３

４
５

６
７

CO
８

９

１０

１１

１９

１２

１３

１４ １５ １６ １７

１８

２０

２１

２５

２２

２３

２４

２７

２８

２６

PY
２９

３０

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

Part Name
Handle post 1
Handle post 2
Handle upper holders
Handle lower holders
Collars
Headlight stay
Speedometer stay
Socket cap screws, 6 x 50
Socket cap screws, 6 x 60
Socket cap screw, 10 x 35
Buttonhead screws, 6 x 25
Buttonhead screws, 8 x 25
Flange U-nuts, 6 mm
Playn washers, 6 mm
Hex nut, 6 mm
Handle post pin
Meter-mount collars
Meter cushion rubbers

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

‑2‑

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

３１

３３
３５ ３４

Part Name
Plain washers, black
HandleSub-harness
Sub-cords, green
Sub-cord, black
Fuel meter cord
Starter switch
Electro taps
Headlight COMP.
Meter assembly
turn-signal lenses (clear lenses)
Heat shrinkable tube
Tie Wraps, 100 mm
L-shaped wrench, 3 mm
L-shaped wrench, 4 mm
L-shaped wrench, 5 mm
L-shaped wrench, 8 mm

３２

Qty
4
1
1
3
1
1
1
5
1
1
2
1
2
1
1
1
1

Jan./09/ 07

〜 Installation Instructions 〜
１．Check the kit contents.
２．Prepare suitable tools for the work.
３．Make sure your bike is secure on a center stand.
４．Referring to the relevant HONDA’s service manual, remove thefollowing parts:

CO・Front cover・Handle front cover・Handle rear cover・Steering handle

５．
Detach a throttle housing, handle bracket L, handle grip L, etc. fromthe removed steering handle.

６．Remove the following parts from a standard handle bracket L, andinstall them onto the prepared turn-signal switch.
The numbers below show the order of removal, and install theseparts in the reverse order of the removal.
① E-clip② Parking lever pivot pin③Parking lever COMP.
④ Lever return spring⑤ Hex nut

⑥ Washer⑦ Spring⑧ Handle lever pivot screw⑨ Rear brake lever⑩ Rear brake cable⑪ Stop switch※ When installing, apply grease to pivots.

７．Fix a handle post pin to a
provided handle post 2.
At this point, fix the pin so thetip of the pin sticks out
somewhat into the inside.

９．Install the handle post 1 with an
8x25 buttonhead screw, andtighten the screw to thespecified torque.
Torque: 22 N･m (2.2 kgf･m)
１０．Loosely install a provided handle pipe for now. And decide theangle at which to install the steering handle, and where to fix athrottle housing and turn-signal switch.
On the clamps of a throttle housing and turn-signal switch, there isa protrusion to position them. In installing them, either shave off the
protrusion or make a hole in the steering-handle pipe.
※ Carefully decide on where to install.
１１．
Please place a steering handle pipe in the handle holder, and then fit
it to the handle post. At this point, put a provided collar into the
spot-facing on the handle-upper-holder front side. Install a
speedometer stay at the same time (See the fig. below). Adjust thesteering handle angle, and tighten the socket cap screw to thespecified torque.
Torque: 12 N･m (1.2 kgf･m)※Tighten the steering-handle holder so the space at the front andback is equal.

PY

Plain washer, 6 mm

Socket cap screw, 6 x 60
Speedometer stay

Socket cap screw, 6 x 50

Front

Collar

１２．Install the throttle housing,handle grip L and others
removed from the standard
handle pipe.

８．Meshing the pin and grooves
on the stem shaft, install thehandle post 2.
After screwing in the pin lightly,
lock the pin with a 6mm hex nut.
Put in a 10x35 socket cap screw
and tighten it to the specified
torque.
Torque: 35 N･m (3.5 kgf･m)

Run the throttle cable, brakehose and brake cable in frontof the handle post.

１３．Install the headlight stay with
a 6x25 buttonhead screw
and 6mm flange U-nut, andtighten it to the specified
torque.
Torque: 12 N･m(1.2 kgf･m)‑3‑

Jan./09/ 07

１４．
Fix a provided speedometer to the stay. The speedometer is to be〜 Starter switch 〜

fixed using a rubber mount system. So, do the installation work
referring to the figure below.

Install the starter switch onto thesteering-handle pipe, and run theharness into the inside of the front
cover of a bike just like other cables.

Meter stay

WasherMeter

CO〜 Stop switch 〜
１．Onto the turn-signal switch, install the removed normal front stop
switch assembly removed from the stock.

Meter cushion rubber

Nut (included in the meter)

Stop switch assemblyMeter-mounting collar

PY

２．
Connect the black, green and yellow terminals of the turn-signal switch
to the terminals of the same color of the stop switch.

１５．Fix a headlight to the headlight stay. Position the headlight andfasten it with a bolt and nut, which please tighten to the specified
torque.
Torque: 25 〜 30 N･m (2.5 〜 3.0 kgf･m)〜 Headlight 〜This kit is designed on the premise that our TAKEGAWA-made Bates-type
headlight is to be used.

１６．This kit is designed on the premise that the provided headlight is to
be used. Attach the headlight to the provided headlight stay.
Set the position of the headlight, and fasten it with a bolt and nut.
Torque: 25 〜 30 N･m (2.5 〜 3.0 kgf･m)
１７．This kit is designed on the premise that the provided aero winker is
to be attached to the normal front cover. So, the work is needed topass the wires through the front cover.
First, make sure where to install the turn signals and where to pass
the wires, and either file down a part of the front cover or make a φ

１．Remove sockets attached to

the Bates-type headlight, andreplace them with a preparedsocket COMP.

２．Connect the blue, white and green cord terminals of the turn signal
switch to the cord terminals of the same color of the socket COMP.

5 or so hole in the cover. (The photo below shows an installation
example.)〜 Turn signal 〜This kit is designed on the premise that our TAKEGAWA-made aero turn signals
are to be used.
Connect the terminals of the right and left turn signals as follows:
Right turn signal: sky blue
Left turn-signal: orange
Earth cable: green※ The aero winker is nonpolar.

Installation of Harness〜 Sub-harness 〜
１．Put the terminal area of the harness from the turn-signal switch
into the headlight case.
２．Then route the remaining part of the harness into the inside of thefront cover just like other cables.
３．With a provided sub-harness, connect two 9-pin couplers of the main
harness on the vehicle and a 9-pin coupler of the turn-signal switch.
NOTE: Be careful not to make wrong connection of couplers.
‑4‑Jan./09/ 07

〜 About wiring of speedometer 〜

How to connect the electro tap

This kit is designed on the premise that our TAKEGAWA-made speedometer isused.
For the power source, connect the meter to a cord from the turn-signal switch.
Connect the + power-source wire to the black, and the earth wire to the green,
respectively.
For the connection, please use an electro tap, or prepare a terminal separately by
yourself.
In case the connection is made with a terminal, branch wires with a provided
sub-harness. (See the fig. below)

CO

②

①
Stopper③
Joining terminal

Vehicle wire
gray harness
cordBlack cord for LED
turn-indicator lamp

Connection
completedSub-cord (gr)orsb

① Before connecting thecords, place them in therelative conduits on theelectro tap. Particularly, set

Turn signals

grMeter (grounding wire)

gr / ylarrow mark (⇒) totemporarily fix the cords.

the position of the LED
cords securely until they

Sub-cord (bk)Turn-signal switch②Fold back the tap at the③Then, fold back thesection with a joining
terminal. Securely
hold it down with a plieror the like until it iscompletely locked.

fully touch the stopper.
Stop switch

bk

Meter (+power source)〜 Fuel meter 〜

PYThis kit is designed on the premise that our TAKEGAWA-made fuel meter kit isused.
１．Remove a rear cover of a fuel meter assembly, and process the wires
as per the figure below. (Connect a provided fuel meter cord (green)using an electro tap.)※ Be sure to insulate the cut-off portions

Fuel meter

Fuel-meter lighting bulb
bl bk
Connect with an electro tap

Cut heregr br bl bk

Fuel meter cordgr

4-pin (rd)Color abbreviation:
Black (bk) ,Blue (bl)Brown (br) ,Green (gr)Orange (or) , Red (rd)Sky blue (sb) , White (wt)
Yellow (yl)※If you are using a compact LCD fuel meter, please refr to its instruciton
manual.
２．After the processing, attach the cover again.
３．
Connect the 4-pin coupler (red) of the fuel meter and the terminal of
the fuel meter cord to the 4-pin coupler (red) of the sub-harness andto the terminal, respectively.
After installation of all hardware, start the engine in a well-ventilated place
to check that all hardware operate normally.
In case you detect some malfunction, please check for the bulb blowout orpoor cord-connection which can be the main cause.
‑5‑Jan./09/ 07

〜 Connection Diagram 〜
wt
bl
gr

Headlight

CO
Right-side turn signal

Left-side turn signal

Stop switch

gr/yl
bk

Stop switch

gr/yl
bk

Turn signal switch for Today※Processing to thefuel meter needed.

Fuel meter※You will not be using
this coupler.

Provided starter switch
bk/wt
bk/yl

sub-cord
gr

or

sb

PY
gr bl wt

bk

gr/yl

In the case of using thestarter switch set for Today

bk
gr/rd

bl/wt

gr

yl/wt

In case you are using
a starter switch set
for Today

Starter switch for Today

gr/yl
yl/gr

bk/yl

gr

bk

gr/yl

bk/yl

※If you use the swtich forToday, process the wires with
an electro tap.

Main wire harness‑6‑

3-5-16 Nishikiorihigashi Tondabayashi
Osaka Japan
TEL : 81-721-25-1357
FAX : 81-721-24-5059
URL : http://www.takegawa.co.jp
Jan./09/ 07

α type Addendum
For tachometer set of large LCD meter αThis page various kit common content.
Please switch the meter setting value according to appropriate vehicle.

CO

Vehicle name
MAGNA50ZOOMER（Carburetor vehicle）
TODAY（Carburetor vehicle）
AF62 DioSPACY100Dio（two‑cycle）
JOG（two‑cycle）
XR50/100 Mptard
XR250 Mptard
KSR110
KSR50/80

Product No.
09‑01‑0211
09‑01‑0056
06‑02‑0303
06‑02‑0301
06‑02‑0305
06‑02‑0302
06‑02‑0304
09‑01‑0288
09‑01‑0055
09‑01‑0054
09‑01‑0054

B

Setting change procedureof tachometer

A

CYC‑
2
2
2
2
2
2
2
2
2
2
2

PIS‑
1
1
1
1
1
1
1
1
1
1
2

Numerical change button (in the text [B] button)
Setting item switch button (in the text [A] button)

Back body

PY

Turn ON the main key of vehicle (starting the engine by vehicle),please state the power of meter has entered (there is a LCD).

Then press the [A]Press the button on the [A].
Display of "CYC‑" appears on the screen.
In this case, will change display alternately with the time you press
the button on [B] "CYC‑2" ⇔ "CYC‑4".

Flashing

Numerical change in [B]Then press the [A]Flashing

To fit to the appropriate vehicle, please select either.
After the selection of CYC‑ is now complete, please press
Display of "PIS‑" appears on the screen.
In this case right side of numerals of the time you press the button on [B] "PIS‑" will change.
Above ‑ if you choose the "CYC 2" it will become a 1⇒2⇒3⇒4⇒1⇒2⇒ ….
It becomes 1⇒2⇒3⇒4⇒5⇒6⇒8⇒1 … If also you have selected the "CYC‑4".
Depending on appropriate vehicle, please select.

Numerical change in [B]Then press the [A]All settings are complete, it will return to standard screen from setting change
screen by pressing [A] button.

Engine Type [CYC‑], about number of cylinders [PIS‑]
This [engine type, number of cylinders], an example of the ignition number of crankshaft rotation.
Therefore, some cases be different from engine type and the number of cylinders of actual vehicle.
0.5 times represents the once ignition to the crank shaft 2 rotation.

Ignition number of times per crankshaft revolution

0.5 times

CYC‑2 （For example of two‑cycle engine）
CYC‑4 （For example of four‑cycle engine）

PIS‑1

1 times

1.5 times 2 times

2.5 times 3 times

4 times

PIS‑1

PIS‑2

PIS‑3

PIS‑4

PIS‑6

PIS‑8

PIS‑2

PIS‑3

PIS‑4

PIS‑5

（PIS‑ the example of the number of cylinders）●When ignition number of appropriate vehicle do not know
Engine types in [CYC‑2] fixed, first set the number of cylinders in [PIS‑4], please check the display numeric value by lightly
blip the engine.
The number of cylinders [PIS‑4] in because it is often actually displayed less than, we will display number is increased bychanging the PIS‑3 → PIS‑2 → PIS‑1 and numbers while watching a state, it becomes just a good set .
Monkey‑based engine, Ape‑based engine, other four‑stroke 1 cylinder, many four‑cylinder engine is set because it is one igni‑
tion per rotation crank shaft 1 will be [CYC‑2, PIS‑1].
In the part of the two‑stroke one cylinder of vehicle and the inner rotor mounted vehicle, there is a case of ignition twice per
crankshaft revolution [CYC‑2, PIS‑2].

Nov./20/ 15