STREET DOWN MUFFLER

Instruction Manual(Product qualified by JMCA or Japan Motorcycle Accessories Association)
Item No.

CO：０４−０２−２３０３ (Standard)：０４−０２−２３０５ (Polished)
Applicable to ：Monkey (FI)Frame No. ：AB27-1900001 〜

Thank you for purchasing one of our TAKEGAWA’s products.
We have designed and manufactured these products, utilizing our own know-how, accumulated over many years, in the product development for Monkeyand Gorilla. We have designed this product to be easy-to-handle to meet any riding purposes. The exhaust pipe is made of highly-corrosion-resistant
SUS304 and the silencer is anodized. This muffler with a built-in catalyzer conforms to the Japanese emission gas standards which came into effect in 2006
in Japan. So, you can ride on the public roads, free from any anxiety in using this product. Before starting the installation, please read this Instruction Manualwell for your thorough understanding and proper installation. Enjoy the sound different from the one from the original muffler.
◎ Please note that, in some cases, the illustrations and photos may vary from the actual hardware.

Please read the following instructions before installation.

◎It is structurally possible to install a standard kickstarter. However, it is advisable to replace the kickstarter arm, for the gap is too small between the armand muffler.
◎ 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 thisone after the installation and use of this product.
◎ Please refrain from combined use of this kit with with any other part than the specified parts.

CAUTIONPY

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.
○This muffler is rising backwards on the right side when viewed in the moving direction. Be careful not to place your legs close to the muffler carelessly
when the engine is running. (Otherwise, you will get yourself burned.)○ 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 not to 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 or suffer
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.)○ You will find it hard to kick down on the kickstarter arm. Press down on the kickstarter arm, being careful not to hit the muffler with your leg.
(Otherwise, you will damage the muffler or get yourself injured.)

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 a safe 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, never place
flammable or hazardous materials such as gasoline near them. (Otherwise, there will be a danger of causing fires.)○ 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.)○ 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.
(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.)‑1‑Nov./09/ 09

◎ 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.
◎ You are kindly requested not to contact us about the combination of our products with other manufacturers'.
◎ This manual should be retained for future reference.

CO〜 Kit Contents 〜

１

３

２

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４No.
1234
5
6
7
8Parts Name
Exhaust muffler comp.
Clamp band
Muffler stayPivot nut
Flange bolt, 8 x 16
Flange bolt, 8 x 20
Flange nut, 8mm
Exhaust pipe gasket

Qty
11111111５６Repair Part Item No.

91140-181-T01
91122-FM2-T00
90140-165-T00
00-00-0039
00-00-0211
00-00-0141
00-01-0064

７８In packs of
1
1
14452

※ Please note that in ordering repair parts, be sure to quote the Repair Part Item No.
Otherwise, we may not be able to accept your orders.
There are some parts, however, for which we are not in a position to accept yourorder in just the quantity to be used. In this case, please take them in the quantity
packed.

‑2‑Nov./09/ 09

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

●Genuine Muffler Removal●Muffler Installation

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１．
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.

Joint nutBolt

１．Remove the used exhaust gaskets in theexhaust port. And fit the exhaust pipe gaskets
coming with the kit into the exhaust port andinstall them.

４．
Fit the muffler COMP. into the exhaust-side
cylinder head, and tighten it loosely for now
with a standard nut.

Gasket

２．Unfasten the hex’ bolt which is fixing themuffler.

Muffler

３．Install loosely for now a muffler stay to thepivot nut with an M8x16 flange bolt.

２．
Remove a nut on the upper part of the right side
rear shock absorber. And install the pivot nut
coming with the kit and tighten it to the specified
torque.
Caution: Never fail to observe the specified
torque.

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Torque : 35 N・m (3.5 kgf・m)

５．Fit the clamp band into the silencer of themuffler COMP., which please install, loosely

３．Demount the muffler from the vehicle.

for now, with an M8x20 flange bolt and flange
nut onto the muffler stay.

Flangenut

Mufflerstay
Flange bolt,
8 x 20Silencer band

‑3‑Nov./09/ 09

６．Squeezing the clutch lever, press down on
the kickstarter arm and check whether or not
it interferes with the muffler.
When it interferes with the muffler, loosen
the bolt on the kickstarter arm and slide thearm outward and tighten the bolt to thespecified torque. And place the muffler in the

８．Tighten the flange bolt for the pivot nut to thespecified torque.
Caution: Never fail to observe the specified
torque.
Torque : 27 N・m (2.7 kgf・m)

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１３．Tighten up hardware to the specified
torque.
Caution: Never fail to observe thespecified torque.
Caution:Do the work only when the engine
and muffler are cool.

position so there is sufficient clearance
between it and the kickstarter arm.

９．Tighten the flange bolt on the clamp band to thespecified torque.
Caution: Never fail to observe the specifiedFlange bolt

Flange bolt
Caution: Never fail to observe the specified
torque.
Torque : 10 〜 12 N・m(1.0 〜 1.2 kgf・m)

Clearance

It is advisable to replace your kickstarter armwith ours.
Made of cast steel : 09-10-004
Made of cast aluminum : 09-10-006
７．Equally tighten standard nuts on the cylinder
head EX port to the specified torque.
Caution: Never fail to observe the specified
torque.
Torque : 10 〜 12 N・m(1.0 〜 1.2 kgf・m)

１２．Start the engine and check hardware for
air exhaust leak.
WARNING：Be sure to start the engine in awell-ventilated place.
∴ If your kickstarter arm is a standard one,
you will find it hard to press down on it.
Be sure to start the engine with great care.

torque.
Torque : 27 N・m (2.7 kgf・m)

The miscellaneous●In case you have replaced a swingarm:о If you have replaced the swing arm on yourmotorcycle, the clearance between the arm andmuffler may be small or these two parts may
interfere with each other, depending on theshape of the swing arm,
If the above case applies, place a 5 to 8mm

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１０．Thoroughly wipe off the dirt stuck on themuffler.
１１．Peel a protective film off a nameplate andJMCA plate on the silencer of the muffler COMP(JMCA: Japan Motorcycle Accessories

thick collar between the pivot nut and muffler
stay in order to keep sufficient clearance
between the swing arm and muffler, and install
the muffler.
In this case, you cannot use the standard
kickstarter arm as it will interfere with themuffler. So, be sure to replace the kickstarter
arm.
Made of forge steel : 02-08-0043
Made of forge aluminum : 09-10-006

Association).

Pivot nutCollar

This is a bolt longer
by collar thickness

Muffler stay

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‑Nov./09/ 09