Hyper S-Stage KIT Instruction manual
Product number 01-05-0243 (High Flow Filter)

Adaptation model

CRF50F (AE03-1400001 ～ )XR50R (AE03-1000001 ～ )Thank you very much for purchasing our products.
Thank you so you will comply with the following matters at the time of use.Before installation, please check your always kit contents.
If there is a point of notice event, Please contact us the dealer of purchase.
◎ If the description, such as photos or Illustration different with this part.

Caution about FuelThis S-Stage Kit is so designed to achieve a higher compression ratio than stock engines. As for the fuel, high-octane gasoline
should always be used. In case regular gasoline is used, abnormal combusiton will take place, and you cannot get the high performanceof the Kit. Moreover, it is highly likely that the piston will be damaged, leading to a serious failure of a motorcycle.
Before installing this kit, make sure that no regular gasoline remains in the fuel tank. In case regular gasoline is remaining in thefuel tank, do replace it with high-octane gasoline.

Caution about Spark PlugCOBe sure to replace a spark plug with a CR8HSA (NGK) or U24FSR-U(DENSO). In the case of a non-resistive plug, please replace withC8HSA (NGK) or U24FS-U (DENSO). Subsequently, choose and use a right spark plug with the right level,depending on the degree ofburning of the spark plug electrode section.

Caution about sprocket

The installation of this product will increase the power of your vehicle. So use of a stock sprocket will result in severe wears ofparts because of too low gear, not only adversely affecting the engine life, but also possibily breaking the engine in the worst case.
Please replace the sprocket with the high-geared one.

☆ Please read carefully before use ☆

◎ 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 kind of warranty whatsoever of products other than this product if the glitch takes place on the otherproducts than this one after the installation and use of this product.
◎ 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.
◎ Do the installation work correctly referring to the relative genuine service manual for the above-mentioned fitting models.
◎ For installation, please prepare suitable tools and work with reference to the installation instructions with enough care. Besides, thisInstruction Manual and genuine service manuals are prepared for those who have acquired basic skills and knowledge. We, therefore, recommend
those who are technically inexperienced or without sufficient tools to ask a technically-reliable specialist shop for the installation work.
◎ Bolts, nuts and dowel pins will be reused. However, be sure not to use the worn-down or severely-damaged ones, which please do
replace with new ones.
◎ You cannot run the motorcycle in the rain with a kit's filter installed. Otherwise, it could cause the engine trouble.
CautionPY

When the handling of ignoring this display, property damage and human shows the assumption of what injury.

■ Always try to drive your motorcycle at 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 ones, screw them securely up to the specified torque.
(Otherwise, improper tightening may cause parts to come off.)※ As for the cylinder head among others, please be sure to tighten it up to the specified torque.
■ Always use new gaskets and packings. And check those parts, to be reused, for wear and damage. If you find worn or damaged parts,
replace them with new ones.
Warning

When the handling of ignoring this display people died, shows the contents of the serious injury possibility is
assumed.

■ 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.)■ When you notice something unusual 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.)■ 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.)■ Carry out inspection and maintenance of your motorcycle correctly according to the instructions and guidelines in the instruction
and service manuals.(Improper inspection or maintenance could lead to accidents.)■ If you find damaged parts when inspecting or 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.)■ As gasoline is highly flammable, never place it close to fire. Make sure that nothing flammable is near the gasoline. Since vaporized
accumulation of gasoline is at high risk of explosion, work in a well-ventilated place. (Otherwise it may cause a fire.)◎ Please note. Performance up, the design change, the product and the price in the cost up, etc. are subject to change without notice.
◎ 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 the like.
◎ Keep this manual stored until this product is discarded.
CONTACT Address : 3-5-16 Nishikiorihigashi Tondabayashi Osaka JAPANTEL: +81-721-25-1357 FAX:+81-721-24-5059 e-mail:english@takegawa.co.jp URL http://www.takegawa.co.jp
Please contact with your name and country name provided. (Only English please)2023.8.24

01-05-0243

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Product content

01-02-517
Piston kit
①

⑤

⑥

⑦

②

③
④

CO

⑧

⑩

⑫

⑬

⑮

⑯

⑰

⑭

⑨

⑪

⑱

⑳

⑲

㉑

㉒

㉔

NumberProduct content
1
Piston2
Piston ring set
3
Piston pin, 13x36
4
Piston pin circlip
5Cylinder6
Cylinder gasket
7
Cylinder head gasket
8
Cylinder head cover gasket
9
Right side cover gasket
Left side cover gasket
10
11 Tappet cap O-ringExhaust pipe gasket
12
Rubber packing
13Camshaft
14
15 DENI18 Carburetor ASSY.

Quantit
1
1
1
2
1
1
1
1
1
1
2
1
1
1
1

㉓

㉖

PY
㉕

Item Number
00-01-0014 (with ③ pin)
01-15-014
00-01-0091 (with ④ clip)
00-01-0003 (6 pcs)
01-01-0241H
00-01-0067 (2 pcs)
00-00-1147
00-01-0156 (2 pcs)
00-01-0157 (2 pcs)
00-01-0158 (2 pcs)
00-01-0034 (4 pcs)
00-01-0064 (2 pcs)
00-01-0066 (2 pcs)
01-08-0009
03-03-0061

㉗

㉘

㉙

NumberProduct content
Intake manifold
16
Air filter (with band)
17
Carburetor gasket
18
Inlet pipe gasket
19
20 Socket cap screw, 6x20
Socket cap screw, 6x25
21
22 Throttle cable, 710mm
23 Spark plug, CR8HSA
24 Main jet, #85
25 Drive sprocket, 15T
26 Tank spacer
27 Flange bolt, 8x25
28 Flange bolt, 8x30
29 Spacer, 8.2x10x9.5
30 Washer㉚

Quantit
1
1
1
1
2
2
1
1
1
1
2
1
1
1
1

Item Number
00-00-1484
03-01-1105
00-03-0417
00-01-0159 (2 pcs)
00-00-0721 (5 pcs)
00-00-0722 (5 pcs)
09-02-0071
00-00-2377
00-03-0041
02-05-022
00-00-0795
00-00-0318 (5 pcs)
00-00-0181 (4 pcs)
00-00-0199 (4 pcs)
00-00-0201 (6 pcs)

※ Please order in the repair parts are always repair part number. If it is not the part number order, you may not be able to order.
Please be forewarned. It should be noted, In the case of parts that can not be separately shipment, please order a set part number.

About bolts:● Usually, counterclockwise rotation loosens the bolts and nuts, and clockwise rotation tightens them.
● When tightening a screw, at first finger-tighten it as tight as you can, without using a tool.
● To loosen a tightened screw means turning it three or four times counterclockwise, and to remove it means turning it aroundcounterclockwise until it comes off.
● To tighten a screw means to tighten it to keep it from getting loose. However, the bolts may break when overtightened, or may getloose or come off because of the vehicle's vibrations when tightened too loosely. The numeric value as a guide at which a screw will
not break or get loose when tightened is the specified torque. And the numeric value varies among the size of the bolts.
● If you do not have a torque wrench, please try to tighten a screw as tight as possible to the extent that the screw will not break or
get loose, though we can not take any responsibility for the screw's breakage or getting loose. In case you do not use a torque wrench,
you need to judge, only by intuition or using experience, the degree of tightening power with which the screw will break or get loose.
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2023.8.24

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Exhaust pipe gasket

Left-side cylinder head side coverLeft-side cylinder headside cover gasket

Dowel bolt, 5 MM

Cam sprocket

Cam shaft COMP.

PY

Tappet adjusting hole cap

O-ring, 30 MM

Cylinder head cover gasket

Hex nut, 6 MM

Sealing washer A, 6 MM
(Copper plated)※1Dowel pin, 8x14

Cylinder head gasket

Inlet pipe gasket

O-ring, 30 MM

Tappet adjusting hole cap※3 Spark plug

※2

※3

※2

※1

Bolt, 6 MM

Cam chain guide roller COMP.

※1 Dowel pin, 8x14

Bolt, 6 MM

Washer, 8 MM

Guide roller bolt

※1 Dowel pin, 8x12

Cylinder gasket

Rubber packing, 16 MM

PistonPiston pin

Piston pin circlip

Piston ring set

CylinderBe sure to change to CR8HSA (NGK) or
U24FSR-U (DENSO).

These hardware is not included in the kit orwill not be used for the installation of this kit.

The length of the dowel pins differs dependingon the use, which please note.

COCap nut, 6 MM

Sealing washer, 6 MM

Cylinder head cover

Valve rocker arm

Tappet adjusting screw

Tappet adjusting nut

Valve rocker arm shaft

Flange bolt, 6x20

Flange bolt, 6x110(Copper or a aluminum)
sealing washer, 6.5 x12

Right-side cylinder head side cover

Right-side cylinder headside cover gasket

Part Names

■ Mounting procedure※ Please refer to the Genuine Service Manual for detailed mounting methods and specified torques that are notspecifically described.

● Removal of standardparts○ Removal of exterior
hardware:○ Remove the carburetor:○ Remove a muffler:○ Remove a crankcase leftside cover:◇ Detach two nuts on the exhaust pipe.

◇ Remove a top cap and pull out
a throttle valve, from the
carburetor.

◇ Unfasten a hex bolt on theshift pedal to remove theshift pedal.

◇ Unfasten each two pieces oftrim clips, screws and bolts
to demount an assembly of aseat, shroud and rear-fender.
Trim clip

Assemly of seat,shroud and rearfender◇ Unfasten a bolt on the muffler
stay to remove the muffler.

Screw◇ Pull out a hose from the storage
tank.

CO

Bolt

◇ You can unfasten the trim clips
by lifting up the inner pin
with a flat tip screw driver.

◇ Unfasten three bolts holding
a crankcase left-side cover.

○ Remove a front fender:◇ Unfasten three bolts on thereverse side to remove thefront fender.

Inner pin

◇ Unfasten a bolt on the aircleaner stay.

○ Remove two tappet caps:◇ Turn off a fuel cock.

◇ Shift the tube clip to
disconnect the fuel tube of
the carburetor.

◇ Remove two tappet caps.

PY○ Remove a spark plug:◇ Unfasten two bolts attachingan inlet pipe to the cylinder
head to remove the inlet pipe,
carburetor, and air cleaner.

◇ Detach a plug cap from theplug by pulling it out.
Be sure to hold the cap inpulling it out.
◇ Remove the plug with an in-vehicle
tool of a spark plug wrench.

○ Remove a cam sprocket:◇ Turn the flywheel
counterclockwise so a“T”markon the flywheel and“O”markon the cam sprocket alignwith each notch.

○ Remove a cylinder-head
left-side cover:◇ Detach a fuel hose from the
carburetor and then unfasten
two bolts to remove the fuel
tank.
Bolt
CollarWasher◇ Fix an earth wire to the framewith a bolt on the air cleaner
stay.

◇ The left-side cover will come
off when a hex bolt in the
middle of the cylinder-headright-side cover is removed.
In case the left-side coverdoes not come off by so doing,screw a few threads of the hexbolt, and strike the bolt headwith a hammer lightly. Then thebolt will come off.

Note: Be sure that you protect
specified torque.
Bolt

01-05-0243“O” mark stamped here
Notch

Flywheel

Torque：12N・m（1.2kgf・m）

Fuel tank2023.8.24

Notch

/11

◇ Holding the flywheel, remove twohex bolts on the cam sprocket.

■ Mounting procedure※ Please refer to the Genuine Service Manual for detailed mounting methods and specified torques that are notspecifically described.

◇ Prize the cam sprocket fromthe camshaft with a smallsized flat tip screwdriver.

◇ Detach the cam chain from thecam sprocket, and take out
the cam sprocket.
◇ Detach a dowel pin fixed in
the center of the camshaft.

○ Remove cylinder head:○ Remove the piston:◇ Remove the cylinder head fromthe cylinder by pulling thehead away from the cylinder. (Ifit does not come off easily,
strike the cylinder head lightly
with a plastic hammer, and it
will come off. )◇ Plug in a waste cloth so as
never to get the dust orcomponent in the cylinder holein the crankcase or cam chain.

CO◇ Remove one of two piston circlips.
It will come off rather easily
if you prize it open with ascrewdriver with its tip on thenotch.

◇ Remove the cylinder head.

○ Unfasten cylinder-headside bolt:◇ Unfasten a cylinder-head sidebolt securing the cylinder
head and cylidner.

Piston circlip◇ Be sure to save two dowel pins
for use later.

○ Remove the cylinder:◇ Remove the loosened guide rollerbolt and cylinder side bolt.

◇ Loosen a side guide rollerbolt on the cylinder and aside bolt between cylinderand crankcase.
Guide roller bolt

Side bolt◇ Remove the piston pin in the
direction where the piston
circlip is not attached. You caneasily remove the piston pin bypressing it with a flat tip
screwdriver from the direction
where a piston pin circlip is
attached.

◇ In fixing the cylinder onto
the crankcase, in some cases
there is interference in thesleeve hole in the crankcase
mating surface, circled
portions, the shaded area ofthe cylinder sleeve, and insideof the crankcase, because theright and left crank cases
are not meshing correctly.
Since the continued use ofsuch crankcase will lead tosleeve deformation and engine
troubles, do not fail to checkthe crankcase for theinterference, and correct theinterference,if any.

PY
◇ Remove the piston.

○ Clean the mounting surfaces:◇ Remove four nuts, which holdthe cylinder-head cover,alternately and diagonally.
◇ Remove four washers beneathnuts.

◎ Cautions for installing
aluminum cylinder◎ Tips on how to fix theinterference◇ Remove the cylinder by pulling
it out. (If it is hard to pull
it out, hit the cylinder lightly
with a plastic hammer.)○ Unfasten cylinder-headcover:◇ Cut off the gasket squeezingout at the section pointed bya finger as shown in the picture.

◇ While removing the cylinder,
the cam chain guide roller will
come out, which please remove.

◇ Remove the cylinder gasket andrubber packing.
◇ In case you cannot remove all
the gaskets completely,rasp or
wipe them off with a scraper orcutter knife.
◇ Cut off the crankcase center
gasket which is squeezing out
into the cylinder base or
cylinder hole,if any.
※ Never let any dirt or component
drop into the crankcase.

1.Cover the crankcase securely
with a waste cloth so theshavings will not get into it.
2.Rasp the higher mating surfaceof the crankcases till it
becomes level with the lowerone.
3.After scraping, remove thecloth with enough care so any
chip will not get into the case.
4.After removing the waste cloth,
stuff up the crankcase opening
with a clean waste cloth.
5.After the installation of theKit, idle away the engine fora few minutes, and replace theengine oil with new one without
delay. And there is nothing
more to do.
Right side
crank case

Left side
crank caseGasketCylinder gasket◇ Remove the head cover. (If it
does not come off easily,strikeit lightly with a plastic
hammer, and it will come off.)If some gaskets remain on thecylinder head, wipe them offcompletely with a scraper ora cutter.

After being fixed◇ After removing the piston,take out the cylinder forward.
Rubber packing
SleeveCylinder2023.8.24

01-05-0243

/11Interfering portion

■ Mounting procedure※ Please refer to the Genuine Service Manual for detailed mounting methods and specified torques that are notspecifically described.
◇ Fix oil ring expanders.

● Installation of
S-Stage Kit◇ Fix the piston so the arrow on
the piston head faces downward,
or to the exhaust side.

◇ Fix the cylinder.

○ Piston Installation:◇ Fix a supplied piston pin
circlip securely to the grooves
for circlip on one side of
the piston.
At this time, attach the piston
pin clip, do not align the end
gap with the piston cut out.

◇ Install the cylinder,by pressing
it inch by inch with fingers,being
careful not to move the piston
ring-end gaps out of alignment.

Exhaust side
◇ Fix a lower oil-ring side rail.

PistonCO◇ It will also be an easy way of
installing the piston to first
insert the piston pin about one
third into the piston.

Circlip
end-gap

Notch◇ Fix an upper oil-ring side rail.

◇ Fix securely the supplied piston
pin circlip to the circlip groove.
At this time, attach the piston
pin clip, do not align the end
gap with the piston cut out.

◇ Once the rings have been fixed
into the cylinder,pass the cam
chain through the cylinder,and
fix the cylinder into the
crankcase.

Left
side

◇ You can rather easily install
the piston pin circlip bypressing
it with a screwdriver, but
taking care not to damage thepiston with the screwdriver.
◇ Apply engine oil to thepiston-ring grooves, and fix
piston rings in the order of an
oil ring expander,lower oil ringside rail, upper oil ring side
rail,second ring and top ring.
◇ Arrange the positions ofpiston ring-end gaps so theymesh with each other.

PY
PistonCirclip
end-gap

Notch◇ Fix the top ring with thestamped surface facing upwards.

Mark
Top ring

Mark◇ Pulling the cam chain, fix theguide roller.

◇ Fix the second ring with thestamped surface facing upwards.

◇ You can rather easily install
the piston pin circlip bypressing it with a screwdriver,
but taking care not to damage
the piston with the screwdriver.
※ Do the work carefully as,in somecases, the circlip comes off flying
while you are pressing it inside.
◇ Remove the plugged waste cloth.

◇ Press in the guide roller so
the center of the guide roller
and guide-roller bolt hole on
the cylinder just mesh together.

○ Installation of cylinder:

120°
120°

120°

Second ring

Side
rails

Expander◇ Apply engine oil to the piston
pin and con’rod, and install
the piston pin.

60° 60°◇ Degrease the gasket-mounting
surfaces of the cylinder andcrankcase.
◇ Check that two dowel pins B(12 mm
in legth) are present. Then,
attach a cylinder gasket and arubber packing.
Cylinder gasket

Dowel pin

Rubber packing

Stamped on the top ringand the second ring.

◇ Apply engine oil onto the insideof the supplied cylinder andspread the oil evenly with fingers.

Top ring(silver side)
Second ring
(Black)Side rail

PistonExpanderPay attention to the crosssection as well2023.8.24

01-05-0243

/11◇ Install the guide roller bolt.
(Tighten it only finger tightat this point.)

■ Mounting procedure※ Please refer to the Genuine Service Manual for detailed mounting methods and specified torques that are notspecifically described.

◇ Install a cylinder side bolt.
(Tighten it only finger tightat this point.)◇ Attach a dowel pin of a stock
cam to the supplied cam.

◇ Attach the cylinder-head-covergasket and head cover.

◇ Attach a head-side bolt.Tighten
fully the guide roller bolts andthe cylinder side bolts whichwere tightened temporarily.
Note: Be sure that you protect
specified torque.
Guide roller bolt

Torque：10N・m（1.0kgf・m）
lower and upper side bolt

Torque：10N・m（1.0kgf・m）◇ Install the tappet screw of
the rocker arm.

Cylinder-head cover gasket○ Change of camshaft:◇ Detach tappet nuts and boltson the rocker arm assembled
into the cylinder head.
At the time the tappet nuts
are loosened, detach thetappet bolts and nuts together.

CO◇ The arrow shows this side should
face downward, or exhaust side.

○ Installation of cylinderhead◇ With thinner, degrease thecylinder head surface and uppersurface of the cylinder.
◇ Fix two dowel pins into thecylinder.

◇ Install the cam-sprocket bolt
into the camshaft. The camshaft
will come out when you pull it
out or strike its head lightly
with a plastic hammer.
Turning the camshaft,detach it.
Never pull it by force.

◇ Attach a head gasket.

Beware of this positioning mark

◇ Install the washer of the head
cover, being careful of thelocation. The copper washer should
be located on the lower left sideof the engine when the engine
is viewed from the front.

PY
Copper washer◇ Apply clean engine oil to a
cam and bearing of the provided
camshaft.

◇ Fit the cylinder head into thestud bolt.
◇ Passing the cam chain throughthe cylinder head,install the
cam chain.

Apply oil here

◇ Install the head nuts, being
careful of the location.
The hex nut should be locatedon the lower right side of theengine when the engine isviewed from the front.

Hex nut

Apply oil here

◇ Install the supplied camshaft
in the reverse order of removal.
Even if you cannot easily fix thecamshaft, fix it manually without
striking it with a hammer.

2023.8.24◇ Hold the cam chain by sticking
the screwdriver through the cam
chain into a middle hole on thecamshaft so the cam chain will
not fall into the cylinder.

01-05-0243◇ Tighten up the head nuts evenly.
(In case a torque wrench is notavailable,tighten them diagonally,
securely and little by little.)
Note: Be sure that you protect
specified torque.
Head nut

/11Torque：12N・m（1.2kgf・m）○ Installation of cam
sprocket:◇ Align the ‟ T”mark on the
flywheel with the notch on the
crankcase.
Notch◇ Set the shaft so the cam top
faces the piston when the cam
sprocket bolt hole is turned
toward the notch on the cylinder
head. This arrangement places
the cam shaft at TDC (Top Dead
Center) on the compression
stroke.
※ In installing the optionalcam, please refer to its
instruction manual.

■ Mounting procedure※ Please refer to the Genuine Service Manual for detailed mounting methods and specified torques that are notspecifically described.

◇ Remove a hex bolt next to thechange-pedal shaft. As thetensioner, guiding the cam
chain, will slacken,it will beeasy to install the cam chain.

Oil will flow out a little
after the bolt is tightened.
Wipe off the oil.

○ Adjustment of tappet
clearance:◇ Turn the flywheel until the“O”
mark on the camshaft and the“T”
mark on the flywheel mesh witheach notch. Though the flywheel
will not stop right at therequired postion because themagnet repels each other, it is
all right if“O”and“T”marks
mesh with each notch at the sametime after fixing the cam sprocket.

CO◇ Tighten a hex bolt on theright side of the cylinder
head as shown by an arrow.
Note: Be sure that you protect
specified torque.
Hex bolt

Torque：12N・m（1.2kgf・m）◇ Check if there is any change
in the tappet clearance.
If the clerance has not changed,
there is no need to readjust it.
However, in case there is achange,readjust the clearance.

Notch◇ Install the cam chain so the‟ O”mark on the cam sprocket
and notch on the cylinder headmesh with each other.
And install the cam sprocket
to the camshaft .

◇ After adjusting the tappet,turnthe flywheel counterclockwise
twice by hand, and then, align“T”and“O”marks each other.

Stamped“O”markCylinder head side

Notch

◇ After fixing the cam sprocket,
attach the bolt.

◇ Fix the flywheel, and tighten
up two cam sprocket bolts.

Note: Be sure that you protect
specified torque.
Cam sprocket bolt

Torque：9N・m（0.9kgf・m）○ Installation of spark plug:◇ Install two tappet caps.

Flywheel side

◇ While tightening a rocker arm’s
adjust screw, tighten the adjustnut to the extent that a 0.05mm
thickness gauge,placed between
the adjust screw and the valve
stem end, can be pulled out
with only a little resistance.
If you have no idea of theproper resistance in pullingout the 0.05mm thickness gauge,then prepare a 0.07mm and 0.03mm
thickness gauges. When the 0.07mm
gauge won’t go in between thespace but the 0.03mm gauge goesin quite loosely, this means thatroughly 0.05mm clearance issecured. Set the space at 0.05mm
both for intake and exhaust.
Valve clearance(intake side)

Note: Be sure that you protect
specified torque.
Tappet cap

Torque：12N・m（1.2kgf・m）◇ Install a provided plug with
in-vehicle tools or spark
plug wrench.
Note: Be sure that you protect
specified torque.
Plug

Torque：11N・m（1.1kgf・m）

PY◇ Attach a plug cap to the plug.

○ Installation of stock
muffler◇ Install a muffler, and a bolt ona muffler stay loosely for now.

○ Installation of cylinderhead left-side cover:◇ Install the hex bolt which
was next to the change pedal
shaft and was just removed.
Note: Be sure that you protect
specified torque.
Hex bolt◇ Attach a cylinder-head left-side
cover gasket and left-side cover.
(Set the anti-rotation stopper ofthe left-side cover to prevent thecover from turning to the rightwhen the bolt is being tightened.)

Valve clearance(exhaust side)
Adjust screw◇ Tighten two nuts on the exhaustpipe, loosely for the moment.

Torque：10N・m（1.0kgf・m）
Thickness gauge
Valve stem

◇ Tighten up the loosely
tightened hardware.
Note: Be sure that you protect
specified torque.
Bolt

Torque：26N・m（2.7kgf・m）
Nut(Set the anti-rotation stopper)

2023.8.24

01-05-0243

/11Torque：10N・m（1.0kgf・m）

■ Mounting procedure※ Please refer to the Genuine Service Manual for detailed mounting methods and specified torques that are notspecifically described.

○ Installation of front
fender:◇ Remove a stock throttle cablefrom the lower throttle housing.

※ Bear in mind that the float pin
is apt to come off.
Float pin

◇ Install the front fender withthree bolts.

◇ Put the carburetor gasket
between carburetor and intake
manifold, and fix the gasket
with two 6x20 socket cap screws.
Note: Be sure that you protect
specified torque.
Socket cap screw

Torque：12N・m（1.2kgf・m）
Carburetor gasket◇ Remove the main jet from thejet holder.

◇ Attach a provided throttle
cable to the lower throttle
housing.

Jet holder
Main jet○ Installation of throttle
cables:CO◇ Remove a top cap fromcarburetor, and pull out aspring and throttle valve.

◇ Disconnect wiring on thestock throttle cable.
◇ Loosen the hex nut.

◇ Install a provided main jet.

◇ Connect an inner cable to thethrottle pipe.

◇ Unfasten two screws to remove
an upper throttle housing.

◇ Detach an inner cable in thethrottle cable from thethrottle pipe.

◇ Install the float chamber, andattach it to the carburetor
with two screws.

PY◇ Fix the upper throttle housingwith two screws.
※ Tighten up the screw in thefront first, and then the one
in the back.

◇ Fix the top cap onto thethrottle cable, and fix thespring, and install the throttle
valve onto the inner cable.

○ Installation of carburetor:◇ Pull out a throttle pipe fromthe steering handle, and cut
off the stopper as shown in
the above photo.

※ In the case of a stock steering
handle, align the joint on thethrottle housing with an“O”
mark on the steering handle.

Anti-rotation stopper◇ Put the inlet pipe gasket
between the intake manifold andcylinder head, and fix the gasket
with two 6x25 socket cap screws.
Note: Be sure that you protect
specified torque.
Socket cap screw

Torque：12N・m（1.2kgf・m）◇ Connect the throttle cablewiring.

○ Change of main jet:
◇ Unfasten two screws to remove
the float chamber.

Inlet pipe gasket

Float chamber◇ Align the notch on the throttle
valve with the throttle stop
screw, and fit the throttle
valve into the carburetor.
Notch
Throttle
stop screw

Screw

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■ Mounting procedure※ Please refer to the Genuine Service Manual for detailed mounting methods and specified torques that are notspecifically described.

◇ Fit the top cover into the
carburetor, aligning the convex
section on the top cover withthe concave section on the
carburetor.

○ Installation of air filter: ◇ Fit the claw at the backside of ○ Installation of drive
the seat into the hook on the
sprocket◇ Attach the band to the air filter,frame, and install an assembly(on the engine side):and fit it into the carburetor.
of a seat, shroud and rear fender.
And fasten the band.

◇ Detach a clip from the drive
chain.

Clip

Claw
Hook

○ Adjustment of throttle
free play:◇ Fit the storage tank hose into
the air filter.

CO◇ Detach a link plate and masterlink to remove the drive chain.
※ Be sure to stop the engine
while you are working.

◇ Roll up a throttle cable's
boot to expose an adjuster.

◇ Holding a hex nut, loosen theadjuster.

More free play

AdjusterHex nut

Less free play

◇ Adjust the free play at thethrottle grip to be about 5mm.

Note: Be sure that you protect
specified torque.
Bolt

Torque：10N・m（1.0kgf・m）
Torque：4N・m（0.4kgf・m）◇ Applying the rear brake,
unfasten two bolts.

PY
Bolt

◇ Remove a plate.

◇ Place a tank spacer between
the fuel tank and frame at thefront part of the fuel tank andfix it with a bolt. And at therear part of the fuel tank,place a tank spacer between theframe and fuel tank, and put aspacer and a provided washer
and attach a bolt.

Right & left screw

Note: Be sure that you protect
specified torque.
Bolt

Right & left trim clip

◇ Pull out a stock sprocket fromthe shaft, and remove the chain.

Torque：26N・m（2.7kgf・m）
Bolt,8x30

Stock collar
Tank spacer

Bolt,8x25◇ Pulling the shroud, align themounting holes with the screw
holes on the fuel tank andattach two screws.
In case you cannot easily put
in the screws, file down theholes to elongate them.

washerCollarTank spacer

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Link plate

Screw○ Installation of exterior
hardware:

About 5 mm

◇ Hold the adjuster and tighten
the hex nut.
◇ By snapping the throttle,
check that the throttle valve
moves smoothly and without ahitch.
◇ Check that there is a little
free play in the throttle evenwhen you turn the steering
handle all the way to theright and left.
◇ Cover the adjuster with theboot.

◇ Install each two pieces ofbolts, screws, and trim clips.

◇ Connect a fuel tube to the
carburetor.

◇ Turning of the adjuster will
adjust the free play.
Throttle cable

Master link

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10/11◇ Fit a provided sprocket into
the shaft.

■ Mounting procedure※ Please refer to the Genuine Service Manual for detailed mounting methods and specified torques that are notspecifically described.

◇ Install a provided plate, andtighten two bolts loosely fornow.

◇ Install a change pedal.
Note: Be sure that you protect
specified torque.
Change pedal

Torque：10N・m（1.0kgf・m）◇ Loosen a rear axel nut andchain adjuster nut.
◇ Fit the master link frominside to connect the drive
chain,and attach a link plate.
◇ Attach a clip.
※ Be sure to attach the clip with
its end-gap in the opposite
direction of driving.

CO◇ Check for slack in the bolts
and the like fixed all the way
from the engine to the suspension.

Driving
direction

Clip◇ Fully tighten the looselyinstalled drive sprocket bolt.
Note: Be sure that you protect
specified torque.
Bolt

Torque：12N・m（1.2kgf・m）◇ Adjust the drive chain.

○ Installation of crankcase
left-side cover◇ Install three bolts to hold acrankcase left-side cover.
Note: Be sure that you protect
specified torque.
Bolt

Torque：10N・m（1.0kgf・m）

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How 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 works well if the cleaner is detached.
・The motorcycle belches dense (or, black) exhaust gas.
・The plug smolders, getting blackened.

・The engine overheats somewhat.
・The engine starts working well If you use the choke,.
・The engine does not accelerate well.
(No smooth acceleration)
・Revolutions change, generating weak power.
・The plug burns white.

CO※ 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)
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.

3rd groove
2nd groove
4th groove

1st groove

5th groove○ Main jet (The throttle position at 3/4 - 4/4)

PY

・The air-fuel mixture ratio at this throttle position can be adjusted by changing the number of the main jet. The larger themain 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.

○ Slow jet / 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 slow jet / pilot jet with a small number.
・If you have tighten the air screw (clockwise) to the full, use a slow jet / 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 theidling to running at slow speed.
・When the engine revolves up unevenly, the slow jet / pilot jet number is too small. (At idle)
・When the motorcycle belches black exhaust gas and produces heavy exhaust sound, the slow jet / pilot jet number is too big. (At idle)
・After replacing the slow jet / pilot jet, you need to readjust the airscrew.

○ Air screw

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:・At highlands or at high altitudes, the barometric pressure and air density go down and the air gets into the carburetor in lessamounts.
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.

CONTACT Address : 3-5-16 Nishikiorihigashi Tondabayashi Osaka JAPANTEL: +81-721-25-1357 FAX:+81-721-24-5059 e-mail:english@takegawa.co.jp URL http://www.takegawa.co.jp
Please contact with your name and country name provided. (Only English please)2022.2.2