COEngine Complete KIT: Spec.SUPER HEAD + R(146 cc)☆SUPER HEAD + R -146
☆ 6-Speed☆SPL- Clutch
Item No.：０１―００―９０１９Compatible models：HC07-1000001〜
Ape100：HC13-1000001〜

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XR100 Motard ：HD13-1000001〜

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.
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．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.
６．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.
７．These instructions should be retained along with this product.

‑A1‑

Dec./05/ 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.

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

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・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‑

Dec./05/ 11

●Use of Roller Rocker Arm:CO

Features● Use of close ratio transmission:◇We have used roller bearings in the slipper instead of a conventional slipper type rocker arm. The use of theroller bearings helps to reduce friction and makes possible the smooth and constant tight grip on a cam profileat all revolutions from low-speed to high-speed.
Besides, the increased weight through the use of roller bearings is counterbalanced through the use of analuminum-forged rocker arm.
Consequently, the higher power output and sustainability on high power have been realized.

●Use of Big Valve:◇ Standard equipped special 6 speed close ratio transmission can transfer the high-power to the road in any
condition the turns and straightway.

●Use of Lightweight Outer Rotor ACG◇ SS outer rotor also equipped as standard. It is narrowed about 80%( φ 110mm →φ 88mm) and weightreduced about 50% (1065g → 536g) to leave inertia force. You can also change the ignition timing by rotatebase plate. Adjustable range : BTDC 27-43, (50cc stock/27,100cc stock/30)◇ Valve diameter Intake：28.5mm / Exhaust：23.5mm which generates great horsepower with large valve andbest valve angle brings high combustion efficiency.

●3 Kinds of Option Cam:

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◇Camshafts are available in three types - SR-25 / SR-30 / SR-35. You can change the camshaft to suit for yourpurpose and riding style such as street and dirt.

●The hollow camshaft◇The oil passage at the center of camshaft leads oil to cam sprocket. Then the oil from the center of cam
sprocket will be injected to lube the cam chain by spinning force. Also, camshaft has oil jet outlets. Oil will be
injected from cam surfaces on the way to cam sprocket so that the cooling and lubrication will be achieved
effectively.

●Use of Plated Cylinder:◇The cylinders are made from all aluminum ceramic plated cylinders with large fin with forged piston, which
are super in durability, gas-tightness and heat transfer.

● Use of Oil Jet:

◇The cylinder has oil jet. It injects the oil from cylinder sleeve to inside wall of cylinder, behind the piston and thesmall end of connecting rod directly; the lubrication and cooling of engine will work efficiently.

● Use of Wet Multiple-Disk Clutch:◇ The 6 disc’s Heavy-duty Clutch kits to avoid clutch slipping caused by high-powered engine. This clutch
cover has oil outlets to oil cooler and optional Thermo unit can be installed on the clutch cover. (Patented)‑A3‑

Dec./05/ 11

CO〜 Kit contains 〜

１

４

２

３

９

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

８

１０

６

５

７

Part NameEngine COMP.
Spark plug, ER8EH
Plug sleeve
Spark plug cap
Clutch cable COMP., 900 mm
Clutch cable receiver
Hyper CDI
Exhaust pipe gasket
Plug socket, 13 mm
Alumi special (5 g)
Copular (2pin /male)
Copular (3pin/male)
SleevePlug
Shrink tube
Stator wiring

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Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

Repair Part Item No.
NGK-ER8EH
12351-KN4-T10
30700-DSM-t00
00-02-0158
50135-GN1-T00
05-03-0005
00-01-0027
00-00-0247
00-01-0001
00-00-0345
00-00-0346
00-00-0347
00-00-0348
00-00-0349
32100-KTK-T00

In packs of
1
1
1
1
1
1
2
1
1
3
3
5
5
3
1

※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.

１１ １２ １５

１３ １４

１６

‑A4‑

Dec./05/ 11

COMain Reference Value
4-cycle gasoline
Type
Displacement
146.3cc
Number of cylinder and arrangement Vertical single cylinder
Cooling method
Air-cooling
Valve train
Chain drive and SOHC
Chamber design
Dome
Bore and Stroke
62mm x 48.5mm
Compression ratio
13.4 : 1

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

Camshaft type
Valve timing:
IntakeopenclosedExhaust open
closedSR-35 (O / P)
(1mm lift)
30°BTDC
60°ABDC
60°BBDC
30°ATDC

Lubricating method
Pump type
Capacity

Combined use of force feed system & splash lubrication system
Trochoid type1.01 liter

Fuel to be used

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

Ignition system
Spark plug

CDI ignition
NGK-ER8EH

Starting method

Primary kickstarter system

Power transmission
ClutchOperating mode
Transmission
Type
Gear ratio
1st speed
2nd speed
3rd speed
4th speed
5th speed
6th speed
rear-wheel-drive mechanism
Type

Wet multi-disk
MechanicalConstant mesh, 6-speed return2.642 (14 / 37)
2.000 (17 / 34)
1.631 (19 / 31)
1.380 (21 / 29)
1.173 (23 / 27)
1.040 (25 / 26)

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-C2,C3
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.

PY☆ Please keep it because customers will purchase specifications specifications table.
When spare parts purchase, check specifications, please consider from refer to parts list
included.
Especially parts selection, specifications for sure and, please refer to the parts list o/p page.

O / P : optional parts

Chain drive‑A5‑

Dec./05/ 11

CO〜 Precautions of Use 〜

About the specifications of motorcycle to equip

About oil cooler:◇ Carburetor mount of this engine kit designed differ than that stock engine. You need to have our carburetor
kit for this engine.Please refer optional parts list (page D)◇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.

Compatible Specifications Data Chart
Carburetor
Exhaust system
Oil catch tank

Stock (Inapplicable) ×
Need to modified
Stock (Inapplicable) ×
Need to modified
Need to Install

Takawagas Keihin PE28

(See P-D)● When you use breather kit (optional) always equip oil catch can at the same time.
Due to large displacement engine, blow- by gas volume may increase. Larger capacity catch can are highly
recommended. (approx 500 cc)

Need modified exhaust.
(See P-D)

Equipped as necessary(See P-D)

We recommend to use it according to the heat increase.

Oil cooler

About upper limit of revolution:(See P-D)

Drive /

Stock (Inapplicable) ×

Driven sprocket

Spec Modification

About fuel:Final Gear Ratio 2.5〜2.06 (for 12-inch)(See P-D)◇ Whenever regular gasoline is remaining in the fuel tank, always replace it with high-octane gasoline.

For use engine oil◇The upper limit of revolutions varies depending on the installed camshaft and other factors. Please install a
revolution counter to make sure that you drive the engine at revolutions below the upper limit, referring to theCamshaft Comparison Data List.
◇ Take note that engine racing and sudden acceleration, particularly in the 1st or 2nd gear, tend to exceed theupper limit of revolutions.

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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.

◇Engine oil, please use the recommended engine oil.
Recommended : Select a viscosity at ambient temperature and use applications based on the Honda genuine
Ultra G2 or S9 (for 4-cycle motorcycles) SAE10W-30.
If you use equivalent, should meet these conditions.
・API classification SF, SG or, SG class or higher or equivalent
・JASO standard : MA,MB・SAE standard : Please use viscosity oil in accordance with outside air temperature.
See table of oil suction procedure page.

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

Note) engine oil, please use the recommended engine oil.Depending on the type of engine oil, there is what isincluded additives, etc., when used with such engine oil, in the worst case not only adversely affectengine, possibility of engine failure in parts broken.

Engine No.stamped here.
149P-100**‑A6‑

Dec./05/ 11

● About optional cam shaft:

CO○ The following camshafts compatible with this kit are available from us. Referring to the list below, please
select a camshaft to match the use, for your great riding pleasure.
You can choose one as an optional part if it matches your bike after confirming the specifications.

SR-25 cam shaft
SR-30 cam shaft
SR-35 cam shaft

01-08-0447
01-08-0446
01-08-0445

124cc
146cc
Option○ About the descriptions of camshafts and numbers
The bigger the numbers of XX/YY are, the wider the durations are. With these camshafts, the output power
will produce more to high rpm range.
While the smaller the numbers are, the narrower the durations are. With these camshafts, the output power
will produce more to low-to-mid rpm range. The output features are different from each size.
When purchasing our optional camshafts, please choose the camshaft to suit your riding purpose referringto the camshaft data chart.

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Also, the engine output will vary significantly depending on the used exhaust system, length of inlet pipe,
carburetor diameter, compression ratio, ignition timing, fuel or the natural phenomenon such as ambient
temperatures or atmospheric pressure.
(See P-D)

Co.,Ltd.
3-5-16 Nishikiorihigashi Tondabayashi Osaka Japan‑A7‑

TEL : 81-721-25-1357 FAX : 81-721-24-5059 URL : http://www.takegawa.co.jp
Dec./05/ 11

CO

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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.
●Connect ACG●Installation of clutch cable:○ Replace clutch cable receiver (included) and set tothe frame.

○Replace the CDI with the supplied CDI referring to theservice manual of your vehicle.
○May need to modify wiring diagram to match the main
wire harness. Need.

○ Attach a clutch cable to the clutch lever, and routethe cable to the clutch cable receiver, being careful
not to stretch it too tight.

26N･ m(2.7kgf･ m)

Clutch cable

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26N･ m(2.7kgf･ m)

Y

LG

B/Y

Unused wire must cover with shrink
tube to avoid touch other parts.

Ape100 : HC07-1600001〜○ Attach the cable at cable receiver.

: HC13-1000001〜

Use 3P copular.

Receiver

Modify to male terminal at blue / yellow wire.

Y⑥Cable receiver

Use 3P copular.

Y

44N･ m
(4.5kgf･ m)

Clutch lever COMP.

Ape100 : HC07-1000001〜1599999

LG

XR100Motard : HD13-1000001〜
Use 2P
copular.

Use included
stator wiring.

○ Install clutch cable.

Caution : Be sure to follow the specified torque.

Y○ Remove the engine and carburetor from the
motorcycle referring to the service manual of yourvehicle.

●Installation of engine

LG●Remove the engine

Clutch lever

Modify to male terminal at blue / yellow wire.

Unused wire must cover with shrink
tube to avoid touch other parts.

LG : Light Green
B
Y
‑B1‑

: Blue: Yellow
Oct./17/ 15

CO●Installation of carburetor:○ Adjust clutch cable and tight lock nut.

Lock nut

Adjust nut

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

Clutch lever○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.

○Start jetting as MJ#110 and SJ#35.
○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.

○ 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.

Less free playMore free play

Caution : Be sure to follow the specified torque.
Torque: 10 N・m(1.0 kgf・m)Insulator●Inspection:☆ In the case of PE28:○ Read installation manual for carburetor.
○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 throttlepipe.
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.
○ Install insulator rubber to the cylinder head.

Adjuster

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About 5 mm

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

‑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.

Oct./17/ 15

CO○ Dispose of the blow-by gas from the crankcase by
yourself.
(Some races and regulations stipulate the blow-by
gas disposal.)○ To return blow-by, please connect to air filter.
(See Optional parts chart on P-D1)●Engine oil●Installation of drive chain● Install the exhaust system○ Remove the cap and add 1010cc of engine oil.

○ Remove generator cover.

○ Attach a supplied exhaust pipe gasket to theexhaust port.

○ Referring to the chart below, choose the engine oil
whose viscosity matches the region and outside○ Install the drive sprocket and drive chain.

temperature.

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

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Bolt

○ Install an exhaust muffler according to theinstallation instructions of the relative exhaust
muffler.
Caution : Always read installation manual
before work.

Drive sprocket○Install the oil inlet cap.
○Install a kick starter arm.

Caution : Be sure to follow the specified torque.

○ 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.

Chain clip

Torque: 20N･m (2.0kgf･m)

In the direction of thechain’s movement‑B3‑

Oct./17/ 15

○ Remove cylinder head cover.

CO● Start engine○ Install generator cover.

○ Replace the spark plug. (Kit included)

Caution : Be sure to follow the specified torque.
Torque: 10 N・m(1.0 kgf・m)○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 spark plug with sleeve. Apply “alumi special”
paste.
AL‑SPL○Put some engine oil to the cylinder head.
OIL

Caution : Be sure to follow the specified torque.
Torque: 10 N・m(1.0 kgf・m)Standard timing.30
Ret
arde
d
TDC mark○ Install cylinder head cover to the specified torque.
Caution : Be sure to follow the specified torque.
Torque: 12 N・m(1.2 kgf・m)

Sleeve○ Lose the coil bracket screw and set the timing markto the 30.Tighten screw to the specified torque.

Ad
va
nc
ed

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○ Install change pedal.

Caution : Be sure to follow the specified torque.
Torque: 10 N・m(1.0 kgf・m)‑B4‑

Caution : Be sure to follow the specified torque.
○ 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. Pulla choke lever to start the engine. Gradually loosen
your grip on the lever, and warm up the engine till
the revolution becomes smooth. And then returnthe lever fully back to its original location.
If the engine does not run idle after warming-up, or
it runs idle at high revolutions, adjust therevolutions with the throttle stop screw.

Oct./17/ 15

CO○ 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.
∴ Always keep the oil to the specified level.
(Use the same grade and brand oil.)◎ 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 holeplug (option) into the oil hole.
２．Apply engine oil to the O-rings of the thermostat

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

hole cap, and tighten the hole cap to thespecified torque.
Caution : Be sure to follow the specified torque.
Torque: 13 N・m(1.3 kgf・m)（Oil Cooler Installation）● In case a thermo unit is to be installed:

１．
０Ｌ
０．
９Ｌ
０．
８Ｌ

○ Check for malfunctions such as unusual sounds.
○ If no malfunction is detected, do the setting of the
carburetor.
(See the attached sheet)

１．Install a thermo unit.
２．Unfasten two oil plug bolts, and install an adapter
suitable for the kind of hose you will use.
Then connect the hose.
※Please see the instruction manual for the thermo
unit.
※Please see the instruction manuals for the oil cooler
kit and the adapter.

Warning : Be sure to do the work in a wellventilated place.

○ After the adjustment or setting, carry out ashakedown about 30 to 50 km, and check the valve
clearance again.
IN : 0.08 mm
EX: 0.08 mm
Caution : Be sure to do the work when the engine

Rubber hose

Caution: Never reuse parts which are notsuitable for reuse.
Warning: Those who are technically unskilled or
inexperienced are required not to do
the work.

match the hose to be used. And connect the hose.
※ For details, see the Instruction Manuals for an Oil
Cooler Kit and an Adaptor.

Allegri’s hose

NEVER install a thermo unit or an oil hole plug.
And in case the thermo unit and / or an oil hole plugis installed, DO be sure to remove it or them.

Caution：There is apossibility that theengine isdamaged because
the oil passage willPY

be blocked when
the thermo unit oran oil hole plug isinstalled.

Oil hole plug

Thermostat hole cap

is cool.
○ 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.)∴ Be sure to proceed the inspection referring to the
Owner’s Manual. (Purchase the owner’s manual if
necessary.)

３．Unfasten two oil plug bolts, and fit an adaptor to

In case an oil cooler is notinstalled:

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 theengine is damaged
due to the oil
passage blockage.

Oil hole plugＩＮ ＯＵＴ‑B5‑

Oct./17/ 15

CO

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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:○Detach a plug cap, and then a spark plug with aplug wrench.

●Oil Change:○ Check whether the spark plug in use is the one withthe right heat value, considering the driving situationand purpose. If the plug seems to be over-burnt,○ 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.

change it with a super plug with a one-step higher
heat value.

Standard
・ NGK: ER8EH
DENSO : U24FSR-U

Plug with high thermal value
・ 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.
And when the gap deviates from the benchmark,adjust it by bending the electrode section.

NEW

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○ Install spark plug with sleeve. Apply “alumi special”
paste.
Caution : Be sure to follow the specified torque.

Gap

∴ Gap
Benchmark : 0.6〜0.7 mm

Relationship between
temperatures and viscosity○ Tight drain bolt with sealing washer to the specified
torque.
Caution : Be sure to follow the specified torque.
Torque: 25 N・m(2.5 kgf・m)○ Remove the cap of oil inlet and add 900cc of engine
oil.

Electrodesection○ 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 :900cc
When rebuilt the engine :1010cc○ Referring to the chart below, choose the engine oil
whose viscosity matches the region and outside
temperature.

○ Check if the electrode section is worn out,
corroded or burnt-out, or its insulator is damaged.
When necessary, change the spark plug.

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.

１．
０Ｌ
０．
９Ｌ
０．
８Ｌ

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

Oct./17/ 15

● 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●Adjust the Valve Clearance○ Inspect the free play of clutch lever.

○ Remove cylinder head cover.

10 to 20 mm

Clutch lever

Caution : Be sure to follow the specified torque.
Torque: 10 N・m(1.0 kgf・m)○ Turn the adjust nut of clutch holder and adjust thefree play of clutch lever.

○ 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

Oil filter
00-02-0027

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

○ Remove the generator cover (by unfastening thefive bolts).

Lock nut

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

○ Turn the flywheel and adjust to the top deadcenter(TDC).

O mark○Tighten the lock nuts on clutch lever and clutch cablerespectively.

SpringBlack bolt

‑C2‑

Oct./17/ 15

CO○ Adjust valve clearance. (Use feeler gauge)
IN : 0.08 ~ 0.03 (when cold)
EX : 0.08 ~ 0.03 (when cold)○Adjust and check the valve clearance of all four
valves by inserting a feeler gauge between theadjusting screw and the rocker arm.
IN : 0.08 ~ 0.03 (when cold)
EX : 0.08 ~ 0.03 (when cold)● Adjust cam chain○ Tighten the adjust nut to the specified torque.

○Warm up engine.
○ Lose cam chain adjuster set plate screw.

Caution : Be sure to follow the specified torque.
Torque: 10 N・m(1.0 kgf・m)MarkTensioner adjuster○When tightening the lock nut, hold the adjusting bolt
to prevent it from turning with the lock nut.
Caution : Be sure to follow the specified torque.
Torque: 12 N・m(1.2 kgf・m)

Set plate bolt
Tighten lock nut.
○ Set the adjuster 45 degree lower than standard
position as shown below.

Torque: 12 N・m(1.2 kgf・m)

Tensioner adjuster

PY○ Install cylinder head cover to the specified torque.
Caution : Be sure to follow the specified torque.
Torque: 12 N・m(1.2 kgf・m)○ Set the adjuster 45 degree lower than standard
position as shown below.

Standard position

４５°

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

Mark○Loosen the lock nut and adjusting bolt. The cam chain
adjuster sets automatically when the adjusting bolt isloosened.

○ Re-install the generator cover and tighten to thespecified torque.

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

Loosen lock nut

Standard position
４５°

Mark

Loosen adjust screw.

‑C3‑

Oct./17/ 15

CO○ Start engine and check the noise of cam chain,
if sounds too tight lose set plate and loosen theadjusting bolt to the counter clockwise. Then tighten
set plate to the specified torque.
Caution : Be sure to follow the specified torque.
Torque: 10 N・m(1.0 kgf・m)
LoosenTight

Cam chain tensioner

PY
‑C4‑

Oct./17/ 15

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.

※ 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)

PY
○ 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.

‑C5‑

Oct./17/ 15

CO

PY

PE28 Carburetor
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

Insulator

CO

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

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

03-05-0192 (w / high flow air filter)
03-05-0191 (w / standard air filter)

PY

Outer length: 710 mm

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)

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

Air filter

03-01-1056 (Standard air filter)
03-01-1059 (High flow air filter)

Standard high throttle set

58 mm

30 mm

Big bore carburetor kit

Involute throttle set

for PE28

φ 35

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

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‑

Feb./07/ 10
Sep./17/17

CO

Cam shaftTitanium alloy valve spring retainer

Racing C.D.I. Magnet Kit

01-08-0445 ：SR-25 cam shaft
01-08-0446 ：SR-30 cam shaft
01-08-0447 : SR-35 cam shaft●You can chose from 3 type of camshaft to matchyour riding style and purpose.

05-02-0723

01-12-084○ Excellent startup performance because of ignition at low○Ignition timing adjustable at up to 24 degrees,○Integral ignition coil with built-in CDI unit,

It is made more resistant to corrosion by to havea special coating of the surface.

○Fully-covered stator coil to protect the ignition coil,○Weight saving:
φ58 rotor: 329 g
Stator, including cords: 383 g
Ignition coil, including cords: 370 g○ “ROSSA” (red) as proof of high performance※No charging functions

Quick lever ASSY.

Clutch lever assembly

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

02-01-0601

Steel Drive Sprocket

Titanium alloy tappet adjusting nut
00-01-0172

PY

Driven Sprocket

Ape100This retainer is made lighter. Thus, response to
the high-revolution is improved.

revolution. (Excellent start-up by a kick starter)

Made of lightweight and high-strength titanium alloy.
We actualized it lightweight by changing not only
material but also the hexagonal width, from 9 to 8 mm.
With lightweight, response to the camshaft profile isimproved.

Steel Driven Sprocket: HC13-1000001 〜

Ape100 : HC07-1000001〜

XR100Motard : HD13-1000001〜

02-05-01 (12T Standard)
02-05-02 (13T Standard)

02-05-041 (15T Racing)
02-05-051 (16T Racing)

02-05-03 (14T Standard)

Aluminum
02-07-38 (45T)Steel
02-07-3402 (31T)

02-07-18 (31T)
02-07-01 (33T)

02-07-04 (38T)
02-07-05 (41T)

02-07-39 (47T)

02-07-3403 (33T)
02-07-3401 (35T)

02-07-02 (35T)
02-07-03 (36T)

02-07-06 (42T)
02-07-07 (43T)

Gear Ratio (Final)
Drive

Driven

12T
13T
14T
15T
16T

23T

24T

25T

26T

27T

28T

29T

30T

31T

32T

33T

34T

35T

36T

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

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‑

Feb./07/ 17

Oil cooler
Compact coolCO

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

Thermostat
Only for wet-type clutch cover

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

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

PY

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 backto the filter through the bypass passage. When the oil temperatures rises to more than 70 degrees, the valve opens to let theoil flow to the oil cooler. Thus, the thermo unit serves to prevent the overcooling and to keep the oil at a fixed temperature.

02-01-5052

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

Feb./07/ 17

Oil catch tank
(Box type with separator)

09-04-0854
Tank capacity : 530 cc

Exhaust system

BOMBER L exhaust system
04-02-2583

CO(Box type with separator)

09-04-0852

Tank capacity : 516 cc

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

Feb./07/ 17

COImportant

If you got a kickback at the engine start, the engine will be get damaged.
In the worst case, it would be broken.
In order to prevent an engine kickback, please start the engine by following step.

PY

Lightly press down the kick pedal and find the position that become heavier.
Put it back to the first position when become heavier.
Keep your foot on the kick pedal, and press it to the bottom quickly at a stretch while keeping the throttle
grip at fully closed.

To open the throttle at the engine start is one of the major causes to occur the kickback.
If engine doesn't start, please try several times.
If it still cannot be started, there should be other cause.

<Caution>If the engine is broken by the kickback, high repair cost will be charged.

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

3-5-16 Nishikiorihigashi Tondabayashi Osaka Japan

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

Co.,Ltd.

If the engine is broken by the kickback, high repair cost will be charged.

<Caution>
To open the throttle at the engine start is one of the major causes to occur the kickback.
If engine doesn't start, please try several times.
If it still cannot be started, there should be other cause.
grip at fully closed.
Lightly press down the kick pedal and find the position that become heavier.
Put it back to the first position when become heavier.
Keep your foot on the kick pedal, and press it to the bottom quickly at a stretch while keeping the throttle
In the worst case, it would be broken.
In order to prevent an engine kickback, please start the engine by following step.
If you got a kickback at the engine start, the engine will be get damaged.

Important