Hyper S-Stage V-KIT A Type Instruction ManualThis is a newly introduced kit which can bore up to 88cc with a stock 50cc cylinder head, on which you canenjoy the feeling of a real powerful engine. This kit is designed for you to install as easily as you assemble
a plastic model and have a good time studying the engine structure, as if you enjoy street fashion.

Item NO
０１−０５−０２３３
Monkey / Gorilla Z50J-1300017 〜 1510400

・Thank you for purchasing one of our products. Please strictly follow the following instructions in installing and using the product.
・Before fitting the products, please be sure to check the contents of the kit. Should you have any questions about the product, please kindly contact yourdealer.
◎ Please note that, in some cases, the illustrations and photos may vary from the actual hardware.

CO

Cautions about fuel to use

This S Stage Kit product is so designed to achieve a higher compression ratio than stock engines. As for the fuel, therefore, high-octane
gasoline should always be used. In case regular gasoline is used, abnormal combusiton takes place, and the engine cannot achieve
its original performance. Moreover, it is highly likely that the piston will break down, leading to serious malfunction. Before installing,
make sure that no regular gasoline remains in the fuel tank. In case regular gasoline is remaining in the fuel tank, do replace it with highoctane gasoline.

Cautions about spark plug

Please be sure to replace the spark plug with CR8HSA contained in the kit. Choose and use a right spark plug with the right level,
depending on the degree of burning of the spark plug electrode section.

The cautions about a sprocket

The installation of this product will increase the power of your vehicle. So use of a stock sprocket will result in severe wears of parts
because of the too low gear, not only adversely affecting the engine life, but also breaking the engine in the worst case. With a driving
sprocket in the kit, determin the driven sprocket, and then high-gear the sprocket. Please note that a driven sprocket is not included in
the kit.

PY

Please be sure to read the following before use◎We do not take any responsibility for any accident or damage whatsoever arising from the use of the products 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 other products than thisone after the installation and use of this product.
◎ If you make alterations to the product, we shall be held free from any guarantee of the product.
◎ You are kindly requested not to contact us about the combination of our products with other manufactureres'.
◎This product is designed for exclusive use in the above-mentioned types of motorcycles and frame numbers only. Please take note that this product cannot
be mounted on other types of motorcycles.
◎ Before installation, prepare the tools listed in page 2, and install the parts with utmost care, referring to the “Installation Procedures." In addition, this
instruction munual as well as HONDA's service manual is prepared with those in mind who have basic technical skills and knowledge. So,it is advisablethat those who do not have such tools, or skills or knowledge contact a technically reliable specialist shop for installation.
◎The cylinder and cylinder head gasket in this kit differ from genuine ones in thickness. Please take note these parts cannot be used in combination withother manufacturers’ parts as well as genuine parts. And please use our parts for repairs.
◎ 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 newones.
◎ A stock carburetor will interfere with kit's cylinder. So, please process the interefering part in case you install a stock carburetor.
◎ If you use a stock carburetor, do not remove the air cleaner box, as well as air cleaner elements. If you exchange the carburetor, please have a set
according to the model. Disregarding of these instructions will result in engine troubles and serious accidents.
◎ You cannot run the motorcycle in the rain with kit's filter installed. Otherwise, it could cause the engine trouble.
The following show the envisioned possibility of injuries and damages to human bodies as a result of conduct

CAUTION disregarding the following cautions

・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 toyourself.)・Set torque at a specified level with a torque wrench. Otherwise, improper torque will result in the breakage or coming off of bolts and nuts.
・As some products and frames have sharp-pointed or protruding portions, please work with your hands protected. (Otherwise, you will suffer injuries.)
・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.)・Please replace gaskets and packngs with new ones. As to the parts for reuse, check carefully for wear and/or damage. Always replace worn or
damaged ones with new ones.
The following show the envisioned possibility of the injuries to human bodies or physical damages as a result of

WARNING disregarding the following cautions.

・Please try to ride a motorcycle at legal speed on the public road, abiding by the law.
・Work only when the engine and the muffler are cool. (Otherwise, you will burn yourself.)
・Prepare tools suitable for the work. Otherwise, the parts will be damaged or you will suffer injuries.
・Set torque at a specified level with a torque wrench. Otherwise, improper torque will result in the breakage or coming off of bolts and nuts.
・As some products and frames have sharp-pointed or protruding portions, please work with your hands protected. (Otherwise, you will suffer injuries.)
・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.)
・Be sure to retighten the cylinder head to the specified torque.
・Exchange the gaskets and packings with new ones. And as for those parts to be reused, check them for wear or damages.In case wear or damage
is detected, always replace them with new ones.
◎ Please be informed that, mainly because of improvement in performance, design changes, and cost increase, the product specifications and rices are
subject to change without prior notice.
◎ This manual should be retained for future reference.
‑1‑

Dec./17/ 12

Lesson◇ Bolts and nuts will get loose when turned counterclockwise,and tighten when turned clockwise.
◇ In tightening screws, first finger tighten them as hard as possible without using tools. If they stop turning after giving them one or two turns, the screw
may be fixed at a slant.
◇ To loosen a screw means turning a tightened screw around three or four times counterclockwise, and to unscrew it means turning it aroundcounterclockwise until it comes off.
◇ To tighten a screw means to screw it up to keep it from getting loose. The numeric value as a guide at which a screw will not break or get loose whentightened is the so-called "torque." If you do not have a torque wrench, please try to tighten a screw as tight as possible to the point where the screw
will not break or get loose, though we can not take any responsibility for the breakage. In case you do not use a torque wrench, you need to judge, only
by intuition or using experience, the degree of tightening power at which the bolt will break or get loose.
◇ Improper use of tools will result in breakage of the top of a bolt or screw.

CO◇Kit’s Contents

１

５

３

４

１４

１６

１５

２３

１０

８

１７

２２

２５

２

７

１８

１３

１９

６

１２

１１

◇Required Tools for Installtion

９ １０ １１

１
２

１２

１４

１３

１５

３

１６

４

１７

５
１８
１９

６
２０

７

８

Parts Name
PistonPiston ring
Piston pin
Piston pin circlip
CylinderCylinder gasket
Cylinder head gasket
Cylinder head cover gasket
R.Side cover gasket
L.Side cover gasket
Tappet cap O-ringExhaust pipe gasket
Rubber packing (Black)
Camshaft
DENI18 Carburetor ASSY.
Inlet pipe
Air filter (with a band)
Carburetor gasket
Inlet pipe gasket
Socket cap screw, 6X20
Socket cap screw, 6X25
Throttle cable, 710mm
Spark plug CR8HSA
Drive sprocket（with a plate） 15T
Main jet #85

１
２
３
４
５
６
７
８
９
１０
１１
１２
１３
１４
１５
１６
１７
１８
１９
２０
２１
２２

Torque wrench
Open-end wrench
Open-end wrench
Open-end wrench
Offset box wrench
Offset box wrench
Offset box wrench
Ratchet handle

PY
２１

２０

９

２４

NO
１
２
３
４
５
６
７
８
９
１０
１１
１２
１３
１４
１５
１６
１７
１８
１９
２０
２１
２２
２３
２４
２５

２１
２２
‑2‑

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

8-10 mm10-12 mm12-14 mm
8- 9 mm10-12 mm14-17 mm

Socket 8mm
Socket 10mm
Socket 12mm
Extention bar (small)
Extention bar (midsize)
Spark plug wrench set （in-vehicle）
Cross tip driver (large)
Flat chip driver (midsize)
Flat chip driver EXS
Hex wrench 5 mm
Needle nose plier
Plastic hammer

Thickness gauge
Scraper or cutter

Wire etc
Waste clothEngine oil
Dec./17/ 12

‑3‑Exhaust pipe gasket※1Dowel pin, 8x14

Cylinder head gasket

Inlet pipe gasket

O-ring, 30 MM

Tappet adjusting hole cap※3 Spark plug

※2

Cylinder※3 Be sure to change to CR8HSA (NGK) or
U24FSR-U (DENSO).

Left-side cylinder headside cover gasket
Left-side cylinder head side cover※2 These hardware is not included in the kit orwill not be used for the installation of this kit.

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

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

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)

Cap 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

Names of components

CO

Dec./17/ 12

Stock Parts Removal

2．Fuel Tank Removal

1．Seat Removal

CO◇Remove the hex bolt which is used to fix the muffler
by turning it counterclockwise.
◇Remove the bolt of the air cleaner stay.

◇Turn the fuel cock off.

Tools:
Box wrench 10 mm

Tools:
Box wrench 12 mm
Extension bar (medium)

Extension bar (small)◇Remove the side cover.

◇Remove the nut on the back of the muffler by rotating
it counterclockwise.
Tools:
Box wrench 10 mm
Extension bar (medium)

PY◇Shift the tube clip upward and disconnect the
carburetor’s fuel tube.

◇Loosen the nuts under the seat, and unscrew thebolts.

◇Unscrew two bolts which are fastening the inlet pipe

and the cylinder head together. Then remove the inlet
pipe, the carburetor, and the air cleaner.

Tools:
Box wrench 12 mm
Extension bar (small)◇Remove the two flange collars, and take the muffler
off the body as if by pulling the muffler outward.

Tool:

Offset wrench 8 mm

Offset wrench 10 mm◇Remove the bolts which mount the fuel tank on the frame.
Tool:
Offset wrennch 10 mm

Clump

wire harness◇Shift the wire harness to underneath the frame.

4．Muffler Removal

5．Front Fender Removal◇Remove the fuel tank by pulling it backward.

◇Loosen two nuts on the rear shock.
Tool:

3．Carburetor Removal

Offset wrench 14 mm◇Rotate the two hex bolts on the back of the front fender◇Rotate two nuts on the EX pipe counterclockwise and◇Remove the seat by pullying it backward.

counterclockwise and remove them.

remove them.

Tools:

Tool:
Open-end wrench 10 mm

Box wrench 10 mm
Extension bar (small)◇Detach the carburator’s top cap and take out the throttle
valve from the carburetor.

‑4‑

Dec./17/ 12

6．Spark Plug Removal

11．Cylinder Head Side Bolt Can
Removal9．Two Tappet Cap Removal

13．Cylinder Head Removal◇ Let the front tire down. (Push the valve with the tip ofa cross slot screwdriver or something like this, then
the tire will deflate.Push it till the whoosh cannot beheard any longer.)CO◇Remove the plug cap from the plug by pulling it out
from the plug. Be sure to hold the cap when pulling
it out.

◇Remove the plug by turning it counterclockwise with ◇Rotate the two tappet caps counterclockwise, andremove them.
the in-vehicle spark plug wrench.

◇Rotate counterclockwise the cylinder head side bolt
which are used to fix the cylinder head and the cylinder, ◇Pull the cylinder head away from the cylinder to

Tool:

Offset wrench 17 mm

7．Cylinder Head L Side Cover
Removal

10．Cam Sprocket Removal

and remove the bolt.

remove it. (If the cylinder head does not come out

Tool:
Open-end wrench 10 mmsmoothly, strike it lightly with a plastic hammer.)

Guide roller bolt

Notch

Side bolt◇Remove the cylinder head while pushing the front

PY◇Loosen the cylinder’s guide roller bolt and the side bolt
between the cylinder and the crankcase by rotating

Inscribed “O”◇Unscrew the hex bolt in the center of the cylinder

head right cover, and the left cover comes off.
(If you cannot remove the left cover in this way, screw

Notch

in the hex bolt a few screw threads and strike the topof the hex bolt with a hammer lightly.)
Tool:

Box wrench 10 mmthem.

Tools:
Spanner 10 mm

Offset wrench 10 mm

tire. It seems that at this point, you come tounderstand why you have let the front tire down.

◇Keep the two dowel pins for reuse.

14．Cylinder Removal

12．Cylinder Head Cover Removal

Flywheel◇Rotate the flywheel counterclockwisen, aligning the“T” mark on the flywheel and the “O” mark on the cam
sprocket with each notch.

8．Crankcase L Side Cover
Removal◇Rotate counterclockwise the guide roller bolt andthe cylinder side bolt which were loosened, andremove them.

◇Rotate counterclockwise four nuts which are mounting
the cylinder head cover in a diagonal order, and removethem.

◇Remove four washers under the nuts.
Tool:
Box wrench 10 mm◇Pull and remove the cylinder. (If it does not come out◇Fix the flywheel, turn two camsprocket hex bolts

smoothly, strike the cylinder lightly with a plastic
hammer.)counterclockwise, and remove them.
Tools:◇Unscrew the hex bolt on the shift pedal, and turn the

Box wrench 8 mm
Offset wrench 14 mm (For fixing a flywheel)

shift pedal counterclockwise and remove it.
Tool:
Offset wrench 10 mm◇Remove the head cover. (If it does not come off easily,
strike it lightly with a plastic hammer,and it will comeoff.)
◇If some gaskets remain on the cylinder head, wipe themoff completely with a scraper or a cutter.

◇Remove the cam chain guide which will come out
when you pull out the cylinder.

◇Prise the cam sprocket open with a small flat tip
screwdriver or something like this to remove it from thecam shaft.
◇Turn the three screws which are used to mount the ◇Remove the cam chain from the cam sprocket first, andcrankcase left cover counterclockwise and remove
then remove the cam sprocket.
them.
◇Remove the dowel pin fixed in the center of theTool:camshaft.

◇After the piston has been taken out, remove thecylinder out forward while holding the tire by hand.

Cross tip driver (large)‑5‑

Dec./17/ 12

15．Piston Removal◇In case you cannot remove all the gaskets completely,rasp or wipe them off with a scraper or something else,

S - Stage Kit

exercising great caution not to scratch the crankcase.
If the crankcase center gaskets protrude into the

Installation

cylinder base or the cylinder hole, cut them off.
Be careful not to let any foreign matter fall into the1．Piston Installation

crank case.

CO◇Cover the cylinder hole and the cam chain in the

crankcase with a waste cloth so even a single
foreign matter like a part and the dust will never fall
down into them.

◇If the gaskets run off at the point indicated with a finger◇Fit a piston pin circlip, attached to one side of thepiston, firmly in the circlip groove. In so doing, see to itthat the circlip’s end gaps do not meet with the notch onin the above picture, cut them off.

the pin hole.

Cautions about Alminum
Cylinder Installation

Piston pin circlip◇Remove one of the two piston pin circlips.

◇You can remove it by prising it open with ascrewdriver with its tip on the notch.
Tool:
A tapered flat tip screwdriver

Exhaust markIn some cases, due to right and left
crankcases being out of alignment andL e f tfor other reasons,in installing thesidecyliner, there may be interferance insleeve hole of the crankcase’s mating
surface, circled parts, shaded areasof the cylinder sleeve, and inside thecase. Since such intereferance will leadto sleeve deformation and engine
troubles, do not fail to check and per- ◇You can relatively easily install it by pressing it with aform maintenance.
screwdriver. But take care not to damage the piston withThe difficulty level of the work is quite a screwdriver.
high. So, you may feel like being a pro- ◇A left side piston pin circlip should be installed first.
fessional if you have successfully Tool:
completed the job.
A tapered flat tip screwdriver

PY

How to Modify
1．Cover the crankcase securely witha waste cloth so the shavings willremove it by pushing it up with a flat tip driver from the
not fall down into it.
direction where another piston circlip remains fixed. 2．Rasp the convex portions on themating surfaces of the crankcase
till the surfaces become level.
3．Then, remove the waste cloth withcare not to let the shavings go inside the crankcase.
4．After taken off the waste cloth,thenstuff a clean waste cloth into thecase’s hole.
5．After assembly of the kit is◇Remove the piston.
completed, leave the engine idlingfor several minutes. Right after this,exchange the engine oil for new
16. Removal of a Cylinder Baseone. Then everything is set.
Gasket, an O-ring, and a Dowel
Pin◇Remove the piston pin in the direction where a piston
circlip has already been removed. You can easily◇Fix the oil ring expander.

◇Fix the lower oil ringside rail.

◇Apply engine oil to the ring grooves and install thepiston rings in the following order; an oil ring expander,
an under oil ring side rail, an upper oil ring side rail,
second ring, and a top ring.

◇Arrange the ring-end gaps of piston rings
to meet each other.

◇Fix the upper oil ringside rail.

Top
トップリring
ング
120°

120°

120°

Second
ring
セカンドリ
ング

エキスパンダー
Expanderサイド
レール
Side rings◇Fix the second ring.

60°

60°

Cylinder base gasket“R” is engraved on the uppersurface of the top ring, and“RN” on the second ring top
surface.

O ring◇Fix the top ring.

Top ring
Second ringSide rings

Pistonピスト
ン
ExpanderTake note of cross section‑6‑

Dec./17/ 12

2．Cylinder Installation

3．Camshaft Replacement◇Degrease the cylinder and crankcase sides of thecylinder base gasket surface with thinner or the like.

CO◇Once the rings are set in the cylinder, letting the cam
chain go through the cylinder, fit it into the crankcase. ◇Remove the tappet nut and bolt on the rocker arm
which are installed in the cylinder head. At the time
you have loosened the tappet nut, remove both thetappet nut and bolt at the same time.
Tool:
Offset wrench 9 mm◇Apply engine oil to the piston pin and the connecting
rod, and install the wrist pin.

Exhaust mark◇Fix the cylinder base gasket and a black rubber◇Install the guide roller while pulling the cam chain.

packing.

◇Install the piston with the arrow mark on the head of
the piston pointing downwards (or, to be on theexhaust side).

PY◇Install the cam sprocket bolt to the camshaft, and takeout the camshaft by rotating it. Never try to pull it out
forcibly.

◇Check that the two dowel pins are installed.

◇Install the kit’s camshaft in the order reverse to
installing it.

◇It makes the installation easier to insert the piston pin
one third at first.
◇Fit the kit’s piston pin circlip to the circlip grooves
exactly.

Apply clean engine oil to the cam profile and thejournal of the cam shaft. Even if it is difficult to fit the
cam shaft, never strike it with a hammer, etc. Justpress it by hand.

◇Push it into as aligning the guide roller’s center withthe cylinder’ guide roller bolt.

◇Apply engine oil to the inside of the kit’s cylinder,and
spread it with fingers to be equally applied.

◇Fix the rocker arm’s tappet screw by turning it
clockwise.

◇You can rather easily install it by pressing it into thepiston with a screwdriver, but taking care not to◇Fix the guide roller bolt. (Temporarily tighten it as tightdamage the piston with a screwdriver. Do the job
carefully as, in some cases, the circlip comes off
flying while you press it inside. So, wear protective

as possible by hand. )4．Cylinder Head Installation◇Insert the cylinder while holding the tire.

eyeglasses for your eye protection.

◇Degrease the head surface and the upper surface ofthe cylinder with thinner, etc.

◇Take away the waste cloth.

◇Press the cylinder little by little with fingers, with care◇Install the cylinder side bolt. (Temporarily tighten it astight as possible by hand.)not to move the piston rings’ end gaps.
The degree of difficulty is very high. Do your best!

◇Install two dowel pins to the cylinder.

‑7‑

Dec./17/ 12

CO◇ Install the head gasket.
※The rubber packing (black) and the rubber gasket

The job is very difficult, so do your best!
◇After installing the cam sprocket, screw bolts.

(green) are not used here.

While attaching the camsprocket to the cam chain,install the cam chain to the camshaft aligning the “O”
mark on the cam sprocket with the notch on thecylinder head.

Copper washer◇Install the head cover’s washers and nuts. Above is the◇Pass the cylinder head through the stud bolt while
pushing the tire by hand.
◇Passing the cam chain through the cylinder head,picture of an engine seen from the front. At the lower left
are a copper washer and three iron washers, and at thelower left is a hex nut and the remaining three are cap
nuts.

install it.

◇Fix the cam chain by putting a screwdriver in the

PY
Torque:Guide roller bolt 10N・m (1.0 kgf・m)
Side bolts, upper and lower 10N・m (1.0 kgf・m)

Hex’ nut◇Install the cam shaft washer.

central hole on the camshaft.

◇Fix the flywheel and tighten two cam sprocket bolts.

5．Cam Sprocket Installation
Notch

Torque 9N・m (0.9kgf・m)

Tools:
Box wrench 8 mm
Offset wrench 14 mm

6．Cam Chain Adjustment◇Install the cylinder head cover’s gasket and the head ◇Screw the head nuts equally tight. (If without a torquewrench, tighten them firmly little by little diagonally.)
cover.
Torque 12N・m (1.2kgf・m)
Tool:
Box wrench 10 mm○In case you have adjusted the cam
chain, refer to “23. Checking andAdjusting of Ignition Timing” on page 12.

◇Align the “T” mark on the flywheel with the notch on the
crankcase.

Hole

Pay attention to the arrow.
Adjustment
bolt B◇Take note that the arrow faces downward.

◇Install the head side bolt. Tighten fully the guide rollerNotchbolt and the cylinder side bolt which were temporarily ◇Set one of the cam shaft’s holes at the position to be intightened beforehand.
parallel with the notch on the cylinder head;
Tool:
This arrangement places the cam shaft at TDC
Open-end wrench 10 mm
Offset wrench 10 mm(Top Dead Center) on the compression stroke.
※In the case of optional cam shaft installation, follow the
instructions in its own instruction manual.

‑8‑

Adjustment
bolt A◇Loosen the 8mm nut and the adjustment bolt A, thenit will be adjusted by the spring. But in case thetension of the cam chain is not strong enough,dradually tighten the adjustment bolt B while theadjustment A is still loosened, and then adjust it sothat the there is no slackness between the chain andthe sprocket even if you rotate the flywheel.
◇Tighten the adjust bolt A first, and then the 8mm nut.

Dec./17/ 12

8．Cylinder Head Left CoverInstallation

7．Valve Timing and Tappet
Adjustment

10．Stock Muffler Installation

Very difficult work, and do your best here!

Notch

CO
Engraved “O”

Cylinder head side

Notch

◇While tightening a rocker arm’s tappet screw, tighten◇As to the muffler installation, pass the tail pipe throughthe tappet nut to the extent that a 0.05 mm thicknet

the rear shock first and have the flange part near theexhaust output.

gauge , placed between the tappet screw and the valve◇Fix the cylinder head left cover gasket and the left cover.
stem end, can be pulled out with only a little resistance.
(Set the stopper at the position indicated in the picture
If you have no idea of the proper resistance in pulling out
in order for the Lside cover not to turn clockwise whenthe 0.05mm thickness gauge, then prepare a 0.07mm
tighteing the bolts.)
and 0.03mm thickness gauges.The 0.05mm space iswhen the 0.07mm gauge won’t go in between the space
but the 0.03mm gauge goes in with little resistance. Set
the clearance at 0.05 mm both for intake and exhaust.
Tools:
Needle nose plier
Offset wrench 9 mm
Thickness gauge

Flywheel side

◇Turn the flywheel until the “O” mark on the camshaft
and the “T” mark on the flywheel meet each notch.

Though the flywheel will not stop right at the required
postion because the magnet repels each other, it’s
all right if “T” and “O” marks meet each notch at thesame time after fixing the cam sprocket.

◇Install two flange collars as if to squeeze the exhaust
pipe.

PY
(Set the stopper as shown in the
picture above.)◇After adjusting the tappet, turn the flywheel
counterclockwise twice by hand, and then, align the “T”

Valve clearance(Intake side)mark with the “O” mark.

Valve clearance(Exhaust side)◇Tighten two nuts on the exhaust pipe
(temporary tightening).
Torque 10N・m (1.0kgf・m)
Tool:
Open-end wrench 10 mm◇Check for tappet clearance change. If changed, adjust
the clearance again.

◇Tighten the hex bolt (see arrow) on the cylinder head

Adjustment screw

right side.

◇Install nuts to the back side of the muffler (temporary

Torque 12N・m (1.2kgf・m)
Tool:tightening).
Torque 10N・m (1.0kgf・m)

Box wrench 10 mm

Tools:
Box wrench 10 mm
Extension bar (Medium)9．Spark Plug Installation

Thickness gauge
Valve stem

◇Install and tighten the hex bolt which mounts the muffler◇Install the plug with in-vehicle tools or a spark plug

◇Fix two tappet caps.
Torque 12N・m (1.2kgf・m)
Tool:
Offset wrench 17 mm

wrench.
Torque 11N・m (1.1kgf・m)
Tool:
Spark plug wrench◇Install a plug cap on the plug.

‑9‑(temporary tightening).
Torque 26N・m (2.7kgf・m)
Tools:
Box wrench 12 mm
Extension bar (Medium)◇Tighten fully three sections tightened temporarily
beforehand.
Dec./17/ 12

11．Front Fender Installation

Jet holder

CO◇Fix kit’s throttle cable to the lower throttle housing.

Main jet◇Detach the main jet from the jet holder.
Tool:
Flat tip driver (Medium)◇Tighten and fix the hex bolt at the back of the front
fender.
Torque 10N・m (1.0kgf・m)
Tools:

Box wrench 10 mm

Extension bar (Small)◇Blow up the tire.

◇Connect the inner cable with the throttle pipe.

◇Detach the top cap from the carburetor, and take out
the spring and the throttle valve.

12．Throttleb Cable Attachment◇Unfasten the wiring of the stock throttle cable.

◇Fix kit’s main jet.
Tool:
Flat tip driver (Medium)

PY◇Fix the upper throttle housing with two screws.
※In this case, tighten the front screw first, and then theone on the back side.

◇Loosen the hex nut.

Align like this.

Tool:
Spanner wrench 14 mm◇Fix the float chamber to the carburetor with two screws.

※In the case of a stock handle, set the crank in the throttle
housing at the “O” mark on the handle.
(See the picture above.)◇Unscrew two screws and detach the upper throttle ◇Wire the throttle cable.
housing.
Tool:

14．Carburetor Installation
Inlet pipe gasket

Spanner wrench 14 mm

13．Main Jet Replacement◇Fix the top cap onto the throttle cable, and fix the

Float chamber◇Put the inlet pipe gasket between the intake manifold
and the cylinder head, and fix the gasket by tightening
two 6x25 socket cap screws.
Tool:
Hex wrench 5 mm

throttle pipe.
◇Rasp and take away the part indicated in the figure
below.

ScrewsRasp this
part.

Notch

Torque 12N・m (1.2kgf・m)◇Detach the throttle cable’s inner cable from theThrottle pipe

spring and the throttle valve onto the inner cable.

Throttle
stop
screw

Carburetor gasket◇Unscrew two screws and take off the float chamber.
◇Align the notch on the throttle valve with the throttle

Tool:stop screw, and insert the throttle valve into the

Cross slot screwdriver (Medium)carburetor.

Float pin

◇Put the carburetor gasket between the intake manifold
and the carburetor, and fix the gasket by tightening two
6x20 socket cap screws.
Torque 12N・m (1.2kgf・m)
Tool:
Hex wrench 5 mm
◇Detach the stock throttle cable from the lower throttle ※Take note that the float pin often comes off easily.
housing.

◇Fit the top cap into the carburetor as shown in the
picture above.

‑10‑

Dec./17/ 12

15．Adjustment of Play in the

17．Fuel Tank Installation

Master link

Throttle

CO

Link plate◇Insert the bolt into the lower part of the seat and fix thenut.

◇Install the fuel tank to the frame.

◇Remove the link plate and the master link first, andthen remove the drive chain.
※Do not fail to stop the engine before setting toTorque 22N・m (2.2kgf・m)◇Pull down the boots on the throttle cable to expose theadjuster.

work.

Tools:
Box wrench 12 mm
Extension bar (Small)
Offset wrench 12mm

◇Fix the fuel tank to the frame with a bolt.
Torque 12N・m (1.2kgf・m)◇Holding the hex nut, loosen the adjuster.

◇Remove two bolts, applying the rear brake.

Tool:

Offset wrench 10 mm

Tool:
Spanner wrench 8 mm

Spanner wrench 10 mm

スロッ
トルケーブルThrottle
cable

遊びが多く
Moreなるplay

アジャ
Adjuster
スター

六角ナッ
ト
Hex nut

Tools:PY

Box wrench 10 mm
Extension bar (Small)◇Connect the fuel tube with the carburetor.

遊びが少なくLess なるplay◇Tighten two nuts on the rear shock absorber.

◇By turning the adjuster, you can adjust the degree offree play.

about 5mm

◇Adjust the throttle grip to have about 5mm free play.
◇Fix the adjuster and tighten the hex nut.
Tools:
Spanner wrench 8 mm
Spanner wrench 10 mm◇By turning the throttle, check that the throttle valve◇Remove the plate.

Torque 34N・m (3.5kgf・m)

18．Seat Installation

Tool:
Offset wrench 14 mm◇Take the stock sprocket out of the shaft, and remove
the chain.

◇Install the side cover.

moves smoothly and without a hitch.
◇Check that there is free play in the throttle even when
you turn the handle all the way to the right and left.
◇Replace the boots in the original position.

16．Air Filter Installation◇Fix the hook of the seat tray by inserting it between two
washers of rear shock.

19．Drive (engine side) Sprocket
Installation◇Insert kit’s sprocket into the shaft.

Clip◇Attach the band to the airfilter and insert it into the◇Remove the clip on the drive chain.

◇Install kit’s plate and temporarily tighten two bolts.

carburetor. Tighten the band.

‑11‑

Dec./17/ 12

20．About Driven Sprocket (rear tire side)※ With the change of the driven sprocket, the driven sprocket has to be changed as well, and the sprocket needs to be in high gear.
※Driven sprocked must be determined according to types of a clutch and size of tire. Refer to the following list for the details.
※Driven sprocket is not included in this kit. Please purchase it (or them) separately.
※Before the driven sprocket replacement, you have to remove all belongings to the rear tire. Stabilize the vehicle by a racing stand or
something to suspend the rear tire.

CO★Recommended Sprocket for Hyper S-Stage Kit B Type (for 65kg weight)

Tire size

DrivesprocketClutch

８
inc

１０
inc

Drivensprocket

Ratio

Centrifugal 3speed

１６

３０

１.８７

Stock manual

１５

２５

１.６７

Heavy-duty, Special

１６

２５

１.５６

Stock manual

１６

２５

１.５６

Heavy-duty, Special

１６

２８

１.７５

◇Fix the change pedal.
Torque 10N・m (1.0kgf・m)
Tool:
Offset wrench 10 mm◇Check for slackness of the bolts fixed all the way from the engine to the suspension.

21．About Drive Chain※In some cases, replacement of the stock sprocket with the recommended one will make the drive chain too short even iif the chain isadjusted. In such a case, prepare a drive chain separately and adjust the length. In addition, length of the chain varies according to
the length of a swing arm. Refer to the following list for the detail.

※Stop the engine before starting to work.

★The number of links of a sprocket and a chain

The length of a swing arm, and the number of links of a chain

Drive
Sprocket

DrivenSprocket

Stock swing arm

４ｃｍ Stretch

８ｃｍ Stretch

１２(Stock)３１(Stock)７２(Stock)−−１２(Stock)３１(Stock)７６(Stock)

−

−

１６

３０

７４

７８

８４

１５

２５

７２

７６

８４

１６

２５

７２

７６

８４

１６

２８

−

−

−

◇Check for slackness on the bolts fixed all the way from the engine to the suspension.

Master link

１２ｃｍ Stretch １６ｃｍ Stretch−−

PY◇Turn on the fuel cock.

−

−

９２

１００

９０

９８

９０

９８

◇Improper ignition timing may in some cases result in disfunction and, at worst, serious

９２

１００

breakdown. It is advisable that you should check and perform maintainance for ignition
timing. If you cannot do the work by yourself, have your machine checked by a specialist

23.Checking and Adjusting of Ignition Timing

shop.

◇Fix the master link from the inside to the drive chain, and fit the link plate.

Link plate

Timing light◇Install a clip.
◇With a timing light (000-01-009), check that the “F” mark on the flywheel and the※At this point, the clip’s end gap must be placed in the opposite position to thealignment mark on the crankcase are aligned while leaving the car idle.
traveling direction.
Alignment mark
Breakerbolting screw

Clip

traveling
direction

F- Mark

Breaker plate◇Fully tighten the drive sprocket bolt which was tightened temporarily.
Torque 12N・m (1.2kgf・m)
Tools:
Box wrench 10 mm◇Loosen the breaker bolting screw and move the breaker plate little by little to adjust theignition timing.

Extension bar (Small)◇After the adjustment, turn the crankshaft and align it with the point on which the clearance
opens most widely, and measure the clearance with a thickness gauge.
Point clearance: 0.3-0.4 mm
If the clearance is out of this range, replace the point.

22．Crankcase Left Cover Installation◇Fit three bolts to fix the crankcase left cover.
Torque 10N - m (1.0kgf - m)
Tool:

Co.,Ltd.

Cross slot driver (Large)

3-5-16 Nishikiorihigashi Tondabayashi
Osaka Japan
TEL : 81-721-25-1357 FAX : 81-721-24-5059
URL : http://www.takegawa.co.jp‑12‑

Dec./17/ 12

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:

CO

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)

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 thelocation of the E-ring moves down from the 1st to the 5th groove.

2段目
2nd groove

3段目
3rdgroove
4段目
4thgroove

1段目
1stgroove○Main jet (The throttle position at 3/4 - 4/4)

PY
5段目
5th
groove

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, thedenser 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 runningat 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.

○ 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 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.
◎ 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.
◎ This manual should be retained for future reference.
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
Aug./20/ 09