Z-Style Muffler Instruction Manual

COItem No.

：０４−０２−２３０１

Applicable to ：Monkey ・Gorilla
Frame No. ：Z50J -1300017〜：AB27-1000001 〜

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 the descriptions in this manual like illustrations and photos may differ from the actual hardware.

〜 Features 〜

PY○ This is a genuine-like up-muffler for the Monkey, to which a genuine muffler guard can be installed.
It improves the performance without altering the original look of the Monkey.
○ 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 with any other part than the specified parts.
◎ Though a genuine muffler guard can be fixed as it is, processing is necessary as the guard-mounting portion is partially exposed.
◎ This product is designed for exclusive use in a stock kick starter arm. (In case of TAKEGAWA’s kick starter, the arm will interfere with the genuinemuffler guard.)◎ This product cannot be used together with a (wire-type) Dry-Type Clutch Kit of 02-02-0143. For the installation of the said Kit, the installation of aHydraulic Clutch Kit of 02-02-0144 is necessary.

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 mufflerguard.

‑1‑Apr./11/ 06

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 fuffer 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.

PY

Besides, 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.
◎ A defective product which we acknowledge is caused by product materials or defect in manufacturing will be repaired or replaced with a newone by us at our expense, if and when a claim is filed with us within one (1) month of your purchase. However, replacing of parts shall be madeat users’ expenses. And we shall be held free from responsibility for any defect caused by improper installation or use.
Please be informed that we shall be held harmless against any claim against us whatsoever arising out of use of the products in racing and thelike.
◎ 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 〜
１２４No.
１２３
４５３５Parts Name
Silencer assembly
Exhaust pipe
Collar8x30 mm button head socket screw
Exhaust gasket‑2‑Qty１１１
１１Apr./11/ 06

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

●Genuine Muffler Removal
１．Unscrew the bolts on the air cleaner stay.

●Genuine Muffler Guard Removal
６．After removing two collars on the exhaust

COCAUTION : Work only when the engine andthe muffler are cool.

flange, remove the muffler from the body bypulling it outward.

removed genuine muffler.
２．Unscrew all plus screws which are fixing
the muffler guard to the muffler. Keep thosescrews for re-use.
If the screws are worn or damaged severely,
replace them with new ones.
CAUTION: Plus screws may be very tightly
screwed, so unscrew themwith enough care not todamage their heads.
３．Though the genuine muffler guard canbe installed as it is, the stay, which is fixing
the guard on the exhaust pipe, gets exposed
without processing. Therefore, cut off theunnecessary part.

２．Loosen the band which is clamping thecarburetor and the air cleaner, and remove
the air cleaner.

３．Unfasten the nut on the back side of themuffler.

１．Detach the muffler guard from the just-PY

CAUTION: Once the stay is processed or
cut off, the guard on theexhaust pipe of the normal
muffler will be rendered notinstallable any more.

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

Cut off this part

４．If the exposing portion is cut off, it isadvisable to give a touch-up to the cut

４．
Unfasten two nuts on the exhaust pipe flange.
Keep them for re-use.
If the nuts are worn or damaged severely,replace them with new ones.

surface with a heat-resistant paint toprevent the surface from rusting.

８．Reinstall the removed air cleaner in theorder opposite to its removal.
※ On to a12V motorcycle, never forget installing
earth wires.
Torque : 8 〜 10 N・m (0.8 〜 1.0 kgf・m)
５．Unfasten the hex’ bolt which is fixing themuffler.

‑3‑Apr./11/ 06

●Z-Style Muffler Installation
１．Insert and install a kit’s exhaust pipe gasket
to the exhaust port.

● Final Checking
５．Check the clearance between the silencer’s
exhaust pipe and the rear fender, and thenadjust the positions of the silencer and theexhaust pipe so that they do not interfere witheach other.

CO

２．Temporarily install the silencer assembly tothe vehicle in the following order. First, pass
the rear end of the silencer pipe from behindthe upper part of the right-side rear shock
absorber. Then pass the button head socket
cap screw through the silencer stay. Finally,
pass the collar from behind and temporarily
fix the silencer on the frame.

Collar

Button headsocket screw

To the frame

１．Start the engine in a safe and well-ventilated
place, and check for exhaust leak orintereference.
２．After stopping the engine and after each parthas cooled down to the normal temperatures,
re-tighten all screws and nuts to thespecified torque.

６．Tighten the exhaust pipe flange nuts evenly tothe 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

７．Next, tighten the button head socket screw on
the silencer stay to the specified torque.
Torque : 27 N・m (2.7 kgf・m)
８．Install the genuine muffler guard.
Reuse the genuine plus screws.

３．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.)

４．
Pass the exhaust pipe flange through the studbolt of the cylinder head, and fix it temporarily
with the nuts which were used to fix thegenuine muffler.

９．Check for intereference among the genuine
muffler guard, the muffler, and the frame. If needbe, loosen the screws and nuts on eachsection to adjust the positions to the extent thatthe adjusting does not place too much strain on
the muffler. 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‑

Apr./11/ 06