φ 27 Two-Piece Front Fork Kit for 8 inch Wheel(for bar handle Fork width 174mm / Offset 60mm)
・Thank you for purchasing one of our TAKEGAWA products.
Please strictly follow the instructions to install and use the kit.
・Before installing the kit, please be sure to check the kit contents.
If you have any questions about the kit, please contact your local TAKEGAWA
dealer.

：０６−０１−０２１４ (With fender)：０６−０１−０２１５ (Without fender)
Fits：Monkey BAJA
Frame Nos ：Z50J-1700001〜
Item Nos◎ Please note: Illustrations and photos may vary from actual
hardware.

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.

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.
◎ 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.
◎ If you make modifications to any product supplied here, we shall be held free from any guarantee of the product.
◎ You are requested not to contact us about the combination of our product with other manufacturers'.
◎ Please do the disassembly and installation correctly, referring to a Honda’s service manual for the Monkey or Gorilla.
◎ This Kit is for 8-inch wheels only.
◎ If you use our 8-inch aluminum wheel, please separately purchase 6-mm wheel spacers.
◎ Neither a headlight stay, turn-signal stay nor a steering handle is included in this Kit. So, please purchase each one separately.
◎ Please use our TAKEGAWA-made aluminum headlight stay of either 09-03-007, 008 or 09-03-07S.
◎ The following steering handle types of our make are usable: Racing up, middle up, semi up, and BAT types.

▽

▽

▽

▽

▽

▽

◎ 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, 09-02-0230 or -0231)
High throttle set (cable length: 700 mm) (09-02-0222, 09-02-0232 or -0233)
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)
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.

CAUTION‑1‑

Dec./09/ 10

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.)
・Do not let the oil and grease adhere to the brake lining or brake shoes. If oil or grease adheres to them, change the brake shoe, and degrease
the brake lining. (Otherwise, the adherence may lead to an accident.)
・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.

Kit consists of:
０６―０２―００１７

１

０６―０２―１００２
２

０６―０８―３０３

０６―０２―１００４

３

６
７

２２
２４

８

９

１３

１４ ２０

１６

２１

１７

１５

１０
０６―０２―１００５
１１

２３

４

１２

１８
２８

１９

２５ ２６

２９

２７

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

Part Name
Left-side front fork assembly
Right-side front fork assembly
Fork top bridge
Upper handle holder
Lower handle holder
Steering stem COMP.
Steering lock bracket
Stem nut
Stem nut washer
Front fender
Front fender bracket
Front axle shaft
Front brake panel
Brake arm
Front brake cable (750mm)

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

Repair Part Item No.
51508-GEF-T00
51408-GEF-T01

in packs of
1
1

54411-165-T00
54412-165-T00

1
153601-GEF-T00
54303-165-T00
90503-165-T00
61100-181-T00
61102-181-T00
44301-124-T00
45101-165-T00A

1
1
1
1
1
1
1

45451-165-T00

1

No.
16
17
＊18
19
20
21
22
23
24
＊25
26
27
28
29

Part Name
Head light guard bracket
Socket set screw, 5 x 8
Hex bolt, 5 x 20
Flange bolt, 6 x 15
Flange bolt, 6 x 25
Socket cap screw, 6 x 20
Socket cap screw, 6 x 12
Socket cap screw, 6 x 50
Socket cap screw, 8 x 25
Plain washer, 5 mm
Plain washer, 6 mm
Hex wrench, 2.5 mm
Hex wrench, 5 mm
Hex wrench, 6 mm

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

Repair Part Item No.
in packs of
09-03-06（w/screws）4pcs
1SET00-00-0059
1000-00-0113
500-00-0114
400-00-0115
500-00-0043
1000-00-0116
600-00-0044
300-00-0075
400-00-0118
1000-00-0086
10※ Item numbers marked with an asterisk is not included in the Kit of 06-01-0215.
※ Please order repair parts with the Repair Part Item No. Without the repair part item NO., 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.

〜 Installation Instructions 〜Disassembly:
１．Loosen an axle nut on the front wheel.
２．Before starting the work, stand your bikesecurely on a rear maintenance stand placedon a suitable pedestal under the engine.
※Choose a pedestal of a height so the front
wheel is just off the ground.
３． Remove brake wires on the wheel side.
４．Unscrew four right and left bolts on theheadlight guard to detach the head light
guard.
５．Pull out an axle nut and axle shaft to remove
the front wheel.

６．Unfasten a nut on the lower handle holder atthe back of the top bridge, and demount asteering handle assembly.
７．Unfasten a fork bolt, stem nut and washer toremove the top bridge.
８．Remove a top thread and then a fork assembly.
※ Be careful not to lose bearing balls.

‑2‑

９．Remove a handle lock from a stock steeringstem, which please attach to a steering lockbracket.
Caution: Apply the specified torque.
Torque: 9 N･m (0.9 kgf･m)

Dec./09/ 10

Assembly:
１０．Install the steering lock bracket to thesteering stem with a 6x12 socket cap
screw.
Caution: Apply the specified torque.
Torque: 12 N･m (1.2 kgf･m)

１３．Fit the steering stem into the head pipe, andfinger tighten the top thread as tight as
possible. Move it several times to the rightand left so the bearing may fit right. Give it
1/8 turns backward and check that it moves
smoothly and without rattling.

１６．
Pass two head light guard brackets througheach front fork.
※ Beware of the direction!!

１７．Routing the wire harness in the same way
as the stock one, fit the top bridge into thefront fork and stem shaft. And attach thestem washer and tighten the stem nut tothe specified torque.

１１．Remove a bottom cone race on thesteering stem with a punch driver or achisel, and detach a dust seal and dust
seal washer.
And attach the dust seal washer, dust seal,
and bottom cone race to the duralumin stem
shaft.

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

Dust seal
Dust seal washer

１４．Fit the front fork to the steering stem with thewhirl stop on the axle holder on the rightviewed in the direction of travel. And tighten
an 8x20 steering-stem split clamp bolt loosely
for the moment.

１２．Apply grease to the top cone race andbottom cone race, and attach the bearing
to the steering stem and head pipe, andthen the top cone race to the head pipe.
※In case the balls are not set in the bearing,

１８．Loosen the split clamp bolt on the steeringstem, and adjust the right and left innertubes to protrude in the same length.
※Protrude the inner tube about 30 mm sothe caster angles become the same as thethen install 21 balls each to the bottom cone
race and top cone race.
Before applying grease, first wash thebearing with wash oil. Be careful not to let
the dirt adhere to the bearing.

stock caster angles.

１５．Fit the front fork on the left side in the same
way as you fitted it on the right side.
※ Protruding “Wide” should be installedoutside.
※ In case a front-fork clamp-type headlightbracket is used, fit the headlight bracket into
the front fork.

About
30 mm

Whirl stop

１９．Tighten the split clamp bolt on the steeringstem to the specified torque.
Caution: Apply the specified torque.
Torque: 26 N･m (2.7 kgf･m)
２０．
Tighten a 6x20 split clamp bolt on the top
bridge to the specified torque.

IN
Narrow‑3‑

OUT

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

WideDec./09/ 10

２１．
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 to the specified torque.

２４．（ ０ ６ − ０ １ − ０ ２ １ ４ ）As shown in the photo below, attach a front
fender and bracket with hex bolts and tighten
it. Leave loose for now.

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

5x20 hex bolt

cam from the stock brake panel, which
please attach to our brake panel.
And install our brake arm onto the front
brake cam with a 6x25 flange bolt.
Caution: Apply the specified torque.
Torque: 12 N･m (1.2 kgf･m)※ Tighten the handle holders to be spaced
equally in the front and at the back.

※ Wipe off the old grease on the front brakecam and apply new grease to it.

Bracket２２．With a 6x12 flange bolt which was holding
the head light guard when a stock front
fork was used, fasten for now the headlight guard bracket to the head light guard.

２６．Remove the brake shoe and front brake

5mm plain washer（０６−０１−０２１５）
Install the stock front fender and bolt.
※If you install the horn onto the steering stem,
using a stock front fender, place the horn inbetween the front fender and steering stem.
Install a washer of about 1.5 mm in thickness
in another clearance between front fenderand steering stem, and tighten it with a 6x15
flange bolt.
Caution: Apply the specified torque.
Torque: 12 N･m (1.2 kgf･m)

２７．Install the removed front frame with aprovided axle shaft in the reverse order of
its removal.

Adjust the height of the head light guard,
and tighten four socket set screws.
Caution: Apply the specified torque.
Torque: 6 N･m (0.6 kgf･m)StockfenderHorn
Washer
２５．Unfasten a nut which is holding both the hubon the front wheel and the wheel. And fix the
hub with the air valve on the left.

２３．Install a horn. (The photo below shows thehorn installed onto the steering stem.)※If you install the horn to the steering stem,
fold back the stay as shown in the photo
below, and fix it by tightening up a 6x15
flange bolt.

Caution: Apply the specified torque.
Torque: 25 N･m (2.5 kgf･m)※ If our 8inch aluminum wheel is used, the air
valve should be on the right side. And fix thewheel spacer of 6mm in thickness between
the hub and wheel.

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

２８．Replace the brake wire with the provided
one.
２９．Route the brake wire just as the stock one
was routed, and attach it to the brake panel.
３０．Tighten up the flange cap screw holding
the wheel and hub.
Caution: Apply the specified torque.
Torque: 5 N･m (0.5 kgf･m)

３１．Dismantle the vehicle from themm
About 40

maintenance stand and pedestal.
３２．Tighten the axle nut.
Caution: Apply the specified torque.
Torque: 62 N・m (6.3 kgf・m)‑4‑

Dec./09/ 10

How to change front fork oil:
１．Loosen a fork top bolt.
２．Loosen an axle nut on the front wheel, and detach only a nut.
３．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.
４．Pull out the axle shaft to detach a front wheel.
５．Loosen the split clamp bolts on the top bridge and stem to detach a fork.
６．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.
７．Expand and contract the inner tube to drain the fork oil. (Leave the inner tube facing downwards for a few minutes.)
８．Stand the front fork to inject fork oil.
Fork oil : No. 20
Fork oil amount: 68 cc per fork
９．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.
１０．Install the front fork to the stem and top bridge, and tighten the split clamp bolt loosely for now.
１１．Tighten the top bolt to the specified torque.
Caution: Apply the specified torque.
Torque: 20 〜 24 N・m (2.0 〜 2.5 kgf・m)
１２．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
１３．Install the front wheel in the reverse order of disassembly.
Caution: Apply the specified torque.
Torque: 62 N・m (6.3 kgf・m) for axle nut

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‑Dec./09/ 10