Hyper S-Stage KIT A Type Instruction Manual：０１−０５−００８２
Item No.
Monkey, Gorilla ：Z50J-1300017 〜 1510400
・Thank you for purchasing one of our products. Please strictly follow the following instructions in installing and using the kit.
・Before installing the kit, please be sure to check the kit contents. Should you have any questions about the kit, please contact your local motorcycle dealer.

CO◎ Please note that, in some cases, the illustrations and photos may vary from the actual hardware.

Notice 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 highperformance of 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

Notice about spark plug

Be sure to replace a spark plug with a supplied CR8HSA. And at a later stage, choose and use a right spark plug with the rightnumber, depending on the degree of burning of the spark plug electrode section.

Notice about sprocket

The installation of this Kit will increase the power of your engine. So with the stock sprocket, every hardware will get worn out
soon because of too low gear, not only adversely affecting the engine life, but also possibly breaking the engine in the worst
case. Therefore, judge the right type of a driven sprocket, using the supplied drive sprocket. And make the gear ratio high.
※The driven sprocket is not included in the Kit.

PY

Read all instructions first before starting the installation.

◎ 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 other products 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.
◎ For installation, please prepare suitable tools and work with reference to the installation instructions with enough care. Besides, this instruction manual,as well as a HONDA’s service manual, is prepared with those persons in mind who have basic skills and knowledge. Therefore, we recommend those
who are technically inexperienced or do not have enough tools to ask a technically-reliable specialist shop for the 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 newones.
◎If you use a stock carburetor, do not remove the air cleaner box or air cleaner elements. If you change the carburetor, please do the setting to match
various conditions and specifications of your motorcycle. Disregarding of these instructions will result in engine troubles and serious accidents.
◎ You may not run the motorcycle in the rain with the supplied filter installed. Otherwise, please note, it could cause the engine malfunction.
The following show the envisioned possibility of injuries to human bodies and property damage as a result of disregarding the

CAUTION following.

・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.)※ Be sure to fully tighten the cylinder head 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 themwith new ones.
The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the

WARNING following warnings.

・Always try to drive your motorcycle at a legal speed, abiding by the laws.
・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 abnormal with your motorcycle while riding, immediately stop riding and park your motorcyle in a safe place to check
what has gone wrong. (Otherwise, the abnormality 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.)
・Check or carry out maintenance of your motorcycle correctly according to the procedures in the instruction manual or service manual.
(Improper checking or maintenance could lead to accidents.)
・If you find damaged parts when checking and performing maintenance of your motorcycle, do not use these parts any longer, and replace them withnew 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 accumulationof gasoline is at high risk of explosion, work in a well-ventilated place. (Otherwise, it may cause a fire.)‑1‑

Dec./13/ 12

◎ Please be informed that, mainly because of improvement in performance, design changes, and cost increase, the product specifications and prices are
subject to change without prior notice.
◎ This manual should be retained for future reference.

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 aroundCO

counterclockwise 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.
◇ Kit includes:

５

１

１５

１７

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
26
27
28

２２

１６

２０ ２１

４ ３

１４

２５

２３

２４

１０

７
２

８

６

◇ Tools to use for the installation:

１

PY
２７

２６

１８

１３

２８

９

１９

１１

１２

９ １０ １１

２

Part Name
PistonPisston ring set
Piston pin
Piston pin circlip
CylinderCylinder gasket
Cylinder head gasket
Cylinder head cover gasket
Right side cover gasket
Left side cover gasket
Tappet cap O-ringExhaust pipe gasket
Rubber packing
Camshaft
VM22 carburetor assembly
Intake manifold
Air filter (with a band)
Lock nut, 6mm
Inlet pipe gasket
Socket cap screw, 6 x 25
Socket cap screw, 6 x 30
Throttle cable, 710 mm
Spark plug, CR8HSA
Drive sprocket (with a plate), 15T
Main jet, #105
Insulator
Fuel cockMark set

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

１４

１２

１３

１５

３

１６

４

１７

５
１８
６

１９
２０

７

８
２２

２１
‑2‑

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 8 - 10 mm
Open-end wrench 10 - 12 mm
Open-end wrench 12 - 14 mm
Offset box wrench 8 - 9 mm
Offset box wrench 10 - 12 mm
Offset box wrench 14 - 17 mm
Ratchet handle
Socket 8 mm
Socket 10 mm
Socket 12 mm
Extension (short)
Extension bar (medium)
Spark plug wrench set, an in-vehicle tool set
Cross tip screwdriver (large)
Flat tip screwdriver (medium)
Fine-shaft flat tip screwdriver
Hex wrench, 5 mm
Needle-nose plier
Plastic hammer
Thickness gauge
Cutter knife or scraper
Wire
Waste cloth or rag
Engine oil

Dec./13/ 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./13/ 12

Removal of standard
hardware

2. Removal of fuel tank.

3. Remove the carburetor.

1. Removal of seat.

CO◇Remove the hex nut securing the muffler by turning
it counterclockwise.
Tool to use
Socket, 12 mm
Extension (medium )◇Remove a top cap and pull out a throttle valve, from the◇Turn off a fuel cock.

carburetor.

◇Remove a side cover.

◇Remove the nut, fastened on the rear side of the
muffler, by turning it counterclockwise.

◇Remove the fuel cock and install the one in the kit.

◇Unfasten a bolt on the air-cleaner stay.

Open-end wrench, 19 mm◇Loosen a nut under the seat to remove a bolt.
Tool to use
Socket, 12 mm
Extension (short)
Offset box wrench, 10 mm

Socket, 10 mm
Extension (medium)

Extension (short)

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

Tool to use

Tool to use
Socket, 10 mm

Tool to use◇Detach two collars of the flange and then detach the
muffler from the motorcycle by pulling it outwards.

◇Unfasten two bolts attaching an inlet pipe to thecylinder head to remove the inlet pipe, carburetor, andair cleaner.
Tool to use
Offset box wrench, 8 mm

◇Unfasten the bolt holding the fuel tank to the frame.
Tool to use
Offset box wrench, 10 mm

Clamp

Wire harness

5. Remove a front fender.

◇Move the wire harness so it sits under the frame.
◇Loosen two nuts on the rear shock absorber.
Tool to use

4. Remove a muffler.

Offset box wrench, 14 mm◇Remove two hex bolts on the reverse side of the front
fender by turning them counterclockwise.
Tool to use
Socket, 10mm

◇Pull the fuel tank backward to demount it.
◇Remove two nuts on the exhaust pipe by turning them

Extension (short)counterclockwise.
Tool to use◇Pull the seat backward to demount it.

Open-end wrench, 10 mm‑4‑

Dec./13/ 12

6. Remove a spark plug.

11. Unfasten cylinder-head side bolt.

9. Remove two tappet caps

13. Remove cylinder head.
◇Let air out of a front tire. (At the press of the valve withsomething like a tip of a cross slot screwdriver, thetire will deflate. Continue pressing it till the whooshof air cannot be heard any longer.)

CO◇Detach a plug cap from the plug by pulling it out.
Be sure to hold the cap in pulling it out.

◇With an in-vehicle tool of a spark plug wrench, turnthe plug counterclockwise to remove it.

7. Remove a cylinder-head left-side
cover.

◇Remove two tappet caps by turning themcounterclockwise.

◇Remove the cylinder-head side bolt, which holds thecylinder head and cylinder, by turning it counter◇Remove the cylinder head from the cylinder byclockwise.

Tool to use
Offset box wrench, 17 mm

pulling the head away from the cylinder. (If it does
not come off easily, strike the cylinder head lightly

Tool to use
Open-end wrench, 10 mmwith a plastic hammer, and it will come off. )10. Remove a cam sprocket.

Guide roller bolt

Notch

◇The left-side cover will come off when a hex bolt inthe middle of the cylinder-head right-side cover isremoved. In case the left-side cover does not comeoff by so doing, screw a few threads of the hex bolt,
and strike the bolt head with a hammer lightly.

Side bolt

PY“O” mark stamped here

Notch

Then the bolt will come off.
Tool to use

Socket, 10 mm◇Turn counterclockwise the guide roller bolt on thecylinder and the side bolt between the cylinder and the
crankcase to loosen these bolts.

Tool to use
Open-end wrench, 10 mm

Offset box wrench, 10 mm◇Pressing the front tire, remove the cylinder head.
Now you can see the reason why you have let the airout of the tire.

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

14. Remove the cylinder.

12. Unfasten cylinder-head cover.

Flywheel◇Turn the flywheel counterclockwise so a "T” mark on
the flywheel and “O” mark on the cam sprocket alignwith each notch.

8. Remove a crankcase left-side
cover.

◇Remove the loosened guide roller bolt and cylinderside bolt by turning them counterclockwise.

◇Remove four nuts, which hold the cylinder head cover,by turning them alternately, diagonally, andcounterclockwise.
◇Remove four washers beneath the nuts.
Tool to use
Socket, 10 mm◇Remove the cylinder by pulling it out. (If it is hard to◇Holding the flywheel, remove three hex bolts on thepull it out, hit the cylinder lightly with a plastic
hammer.)cam sprocket by turning them counterclockwise.

◇Unfasten a hex bolt on the shift pedal and remove theshift pedal by turning it counterclockwise.

Tool to use
Socket, 8 mm
Offset box wrench, 14 mm (for holding the flywheel)

Tool to use
Offset box 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, wipethem off completely with a scraper or a cutter.

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

◇Prize the cam sprocket from the camshaft with a small◇Remove three screws which are holding acrankcase left side cover by turning themcounterclockwise.
Tool to use
Cross tip screwdriver, (large)

sized flat tip screwdriver.
◇Detach the cam chain from the cam sprocket, and takeout the cam sprocket.
◇Detach a dowel pin fixed in the center of the camshaft.

◇Once the piston has come out, pull out the cylinder
forward, holding the tire with a hand.

‑5‑Dec./13/ 12

15. Remove the piston.

◇In case you cannot remove all the gaskets completely,rasp or wipe them off with a scraper or something else,
exercising great caution not to scratch the crankcase.
In case the crankcase center gaskets squeeze out into

Installation of S-Stage Kit
1.Piston Installation.

the cylinder base or into the cylinder hole, cut them off.
Never let any dirt, dust or hardware into the crankcase.

CO◇Plug in a waste cloth so as never to get the dust orcomponent in the cylinder hole in the crankcase or
cam chain.

◇Fix a supplied piston pin circlip securely to the grooves◇ Cut off the gasket squeezing out at the section pointed

on circlip on the left-side of the piston.
◇Be sure to set a circlip so its end gap is not on thenotch.

by a finger as shown in the above picture.

Piston circlip◇Remove one of two piston circlips.
It will come off rather easily if you prize it open with ascrewdriver with its tip on the notch.
Tool to use

Flat-tip screwdriver with a fine tip◇Remove the piston pin in the direction where thePrecautions for installation ofaluminum cylinder:

attached.

◇Remove the piston.

16.Remove cylinder gasket, rubberpacking and dowel pin.
Cylinder gasket

Left

In installing the cylinder, in some cases,
due to right-side and left-side crankcases being out of alignment and forother reasons, the sleeve hole of the
crankcase's mating surface, circled
portion, the shaded area of the cylinder sleeve and inside of the case mayinterfere with one another. Since such
◇You can rather easily install it by pressing it into theinterference will lead to sleeve deforpiston with a screwdriver, but taking care not tomation and cause engine troubles, dodamage the piston with the screwdriver.
not fail to check the existence of inter◇Fix the piston pin circlip first on the left side.
ference and eliminate the interference,
Tool to use
if any.
Flat-and fine-tip screwdriver
The difficulty level of the work is quite
high. So, you may feel like having come ◇Apply engine oil to the piston-ring grooves, and fix
close to the professional level if you piston rings in the order of an oil ring expander, lower
have successfully completed the work. oil ring side rail, upper oil ring side rail, second ring,

piston circlip is not attached. You can easily remove
the piston pin by pressing it with a flat tip screwdriverfrom the direction where a piston pin circlip is◇Fix oil ring expanders.

Exhaust mark

side

PY

◇Fix a lower oil-ring side rail.

and top ring.

How to correct and eliminate interference
1.Cover the crankcase securely with ◇Arrange the positions of piston ring-end gaps tomesh with each other.
a waste cloth so the shavings will
not get into it.
2.Rasp the higher mating surface of the
crankcases till it becomes level with
ト
ップリ
ング
Top
ring
120°
the lower one.
3.After rasping the mating surface,remove the waste cloth with care
120°
120°
not to let the shavings get into the
crankcase.
4.After removing the waste cloth, stuff Second
セカンドリング
ring
up the crankcase opening with a
エキスパンダー
Expanderclean waste cloth.
サイドレールSide
rail
5.After the installation of the kit, idle
away the engine for a few minutes,
and replace the engine oil with new60°
60°
one without delay. And there isnothing more to do.
Right-side
crankcase◇Fix an upper oil-ring side rail.

◇Fix a second ring.

Left-side
crankcasegasketRubber packing

Attach the top ring and the secondring with the letter side up.
Be careful that the top ring is brown
and the second ring is black.
◇Fix a top ring.

After correction

トップリ
ング
Top
ring
セカンドリング
Secondring

SleeveInterference

Side
rail
サイドレールピスト
ン
PistonCylinderExpanderPay attention to thecross section as well.

‑6‑

Dec./13/ 12

3. Change of camshaft.

2. Installation of cylinder.
◇Degrease the gasket-mounting surfaces of thecylinder and crankcase.

CO◇Once the rings have been fixed into the cylinder, pass
the cam chain through the cylinder, and fix the cylinder ◇Detach tappet nuts and bolts on the rocker arm
into the crankcase.
assembled into the cylinder head.
◇At the time the tappet nuts are loosened, detach thetappet bolts and nuts together.
Tool to use
Offset box wrench, 9 mm◇Apply engine oil to the piston pin and con’rod, andinstall the piston pin.
Exhaust mark◇Install the cylinder gaskets and rubber packing.

◇Fix the piston so the arrow on the piston head faces
downward, or to the exhaust side.

◇Pulling the cam chain, fix the guide roller.

PY◇Install a cam-sprocket bolt into the camshaft.
Turning the camshaft, detach it. Do not pull it out by
force.

◇Check that two dowel pins are present.

◇Install the supplied camshaft in the reverse order of◇It will also be an easy way of installing the piston toinsert the piston pin a third into the piston.
◇Fix a supplied piston pin circlip securely to the grooves
on circlip.

◇Apply engine oil onto the inside of the supplied

removal.
Apply clean engine oil to the cam top and journal of
the camshaft.
Even if you cannot easily fix the camshaft, fix it
manually without striking it with a hammer.

◇Press in the guide roller so the center of the guidecylinder and spread the oil evenly with fingers.

roller and guide-roller bolt hole on the cylinder justmesh together.

◇You can rather easily install it by pressing it into the◇Tighten the tappet screw on the rocker arm bypiston with a screwdriver, but taking care not todamage the piston with the screwdriver.
Do the work carefully as, in some cases, the circlip
comes off flying while you are pressing it inside.

turning it clockwise.
◇Pressing the tire, install the cylinder.

4. Installation of cylinder head.

So, wear protective eyeglasses for your eyes lest it◇Install the guide roller bolt.

should get into your eyes.

(Tighten it only finger tight at this point.)◇Remove the stuffed waste cloth.

◇With thinner, degrease the cylinder head surface
and upper surface of the cylinder.

◇Install the cylinder, by pressing it inch by inch with
fingers, being careful not to move the piston ring-end
gaps out of alignment.
The difficulty level of the work is quite high. Please try ◇Install a cylinder side bolt.
(Tighten it only finger tight at this point.)
your best.

‑7‑◇Fix two dowel pins into the cylinder.
Dec./13/ 12

CO◇Attach a head gasket.

※The difficulty level of the work is quite high. Please
try your best.
◇After fixing the cam sprocket, attach the bolt. Whileattaching the cam sprocket to the cam chain, install
the cam chain so the “O” mark on the cam sprocket
and the notch on the cylinder head mesh together.
Then, attach the cam sprocket to the camshaft.

Copper washer◇Pressing the tire with a hand, fit the cylinder head
into the stud bolts.

◇Passing the cam chain through the cylinder head,
install the cam chain.

◇Install the head-cover washers and the nuts. (Attach acopper washer and three iron washers at the lower left,
and a hex nut and three cap nuts at the lower right,
when the engine viewed from the front.)◇Hold the cam chain by sticking the screwdriverthrough the cam chain into a middle hole on the

PY
Caution: Apply the specified torque.
10 N･m (1.0 kgf･m)

Hex nut

for a guide roller bolt

10 N･m (1.0 kgf･m)
for lower and upper side bolts

camshaft so the cam chain will not fall into thecylinder.

◇Install the camshaft washer.

5. Installation of cam sprocket.

Notch◇Tighten up the head nuts evenly. (In case a torque◇Attach the cylinder-head-cover gasket and head
cover.

Socket, 10 mm
Caution: Apply the specified torque.
Torque: 12 N・m (1.2 kgf・m)

Tool to use
Socket, 8 mm
Offset box wrench, 14 mm
Caution: Apply the specified torque.
Torque: 9 N・m (0.9 kgf・m)

6.Adjust the cam chain.

wrench is not available, tighten them diagonally,
securely and little by little.)
Tool to use◇Holding the flywheel, tighten up three cam sprocket
bolts.

◇Align the "T" mark on the flywheel with the notch on the○ If you have adjusted the cam chain, do
the work in Step 23 on the next page :Inspect and adjust the ignition timing

crankcase.

hole

Beware of thispositioning markAdjust bolt B

Adjust bolt A

Notch◇The arrow should face downward.

◇Attach a head-side bolt. Tighten fully the guide roller ◇Turn the cam shaft hole to the notch on the cylinder
head. This arrangement places the cam shaft at TDC
bolts and the cylinder side bolts which were tightened(Top Dead Center) on the compression stroke.

temporarily.
Tool to use
Open-end wrench, 10 mm※In installing the optional cam, please refer to its
instruction manual.

Offset box wrench, 10 mm◇Loosen the 8mm nut and the adjust bolt A, then the
cam chain will be adjusted automatically by the spring.
But in case the cam chain is not stretched tight, keep
the loosened adjust bolt A as it is, and graduallytighten the adjust bolt B so that the cam sprocket andcam chain fit together even when the flywheel is turned.
◇Tighten the adjust bolt A, and then 8mm nut.

‑8‑

Dec./13/ 12

8. Installation of cylinder-head left-side 10. Installation of stock muffler.
cover.

7.Adjust valve timing and tappet.
The difficulty level of the work is quite high. Please try
your best.

Notch

CO
“O” mark stamped here

Cylinder head side

Notch

◇While tightening a rocker arm’s tappet screw, tighten
the tappet nut to the extent that a 0.05 mm thickness
gauge, placed between the tappet screw and the valve◇Attach a cylinder-head left-side cover gasket andstem end, can be pulled out with only a little resistance.
left-side cover.
If you have no idea of the proper resistance in pulling out(Set the anti-rotation stopper of the left-side cover tothe 0.05mm thickness gauge, then prepare a 0.07mm
prevent the cover from turning to the right when theand 0.03mm thickness gauges. When the 0.07mm
bolt is being tightened.)gauge won’t go in between the space but the 0.03mm
gauge goes in quite loosely, this means that roughly
0.05mm clearance is secured. Set the space at 0.05
mm both for intake and exhaust.
Tool to use
Needle nose plier
Offset box wrench, 9 mm
Thickness gauge

Flywheel side

◇Turn the flywheel until the “O” mark on the camshaft
and the “T”mark on the flywheel mesh with eachnotch. Though the flywheel will not stop right at therequired postion because the magnet repels eachother, it is all right if “O” and “T” marks mesh witheach notch at the same time after fixing the cam◇In installing the muffler, route the tail pipe inside therear shock absorber first, and then set the flange to
be roughly under the exhaust port.

◇ Install two flange collars squeezing the exhaust pipe.

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

sprocket.

Valve clearance
on the intake side

◇Tighten two nuts on the exhaust pipe, loosely forthe moment.

Valve clearance
on the exhaust side
Adjust screw◇Check if there is any change in the tappet clearance.
If the clerance has not changed, there is no need toreadjust it. However, in case there is a change,
readjust the clearance.

Caution: Apply the specified torque.
Torque: 10 N・m (1.0 kgf・m)◇Tighten a hex bolt on the right side of the cylinder headas shown by an arrow.
Tool to use
Socket, 10 mm

Caution: Apply the specified torque.
Torque: 12 N・m (1.2 kgf・m)

Thickness gauge
Valve stem

Tool to use
Open-end wrench, 10 mm

9. Installation of spark plug.

◇ Attach a nut on the reverse side of the muffler loosely
for now.
Tool to use
Socket, 10 mm
Extension (medium)
Caution: Apply the specified torque.
Torque: 10 N・m (1.0 kgf・m)◇Install two tappet caps.
Tool to use
Offset box wrench, 17 mm◇Install a provided plug with in-vehicle tools or spark
plug wrench.
Tool to use
Spark plug wrench◇Attach a plug cap to the plug.

◇Install loosely for now a hex bolt to hold the muffler.
Tool to use
Socket, 12mm
Extension (medium)
Caution: Apply the specified torque.
Torque: 26 N・m (2.7 kgf・m)

Caution: Apply the specified torque.

Caution: Apply the specified torque.

Torque: 12 N・m (1.2 kgf・m)

Torque: 11 N・m (1.1 kgf・m)‑9‑◇Tighten up three portions which have just been loosely
tightened for the moment.
Dec./13/ 12

11. Installation of front fender.

14. Installation of carburetor.

15. Adjustment of throttle free play.

Lock nutCO◇Fasten two hex bolts on the reverse side of the front◇Attach a provided throttle cable to the lower throttle
fender.
housing.
Tool to use
Socket, 10 mm

Socketcap screws 6x25
◇Fix the cauburetor and inlet pipe with socketcap screws ◇Roll up a throttle cable’s boot to expose an adjuster.
6x25xand lock nuts.
Tool to use

Extension (short)

Hex wrench, 5 mm

Caution: Apply the specified torque.

Open-end wrench, 10 mm

Torque: 10 N・m (1.0 kgf・m)

Caution: Apply the specified torque.

◇Pump a tire.

Torque: 10 N・m (1.0 kgf・m)

12. Installation of throttle cables.

◇Disconnect wiring on the stock throttle cable.

◇Holding a hex nut, loosen the adjuster.
Tool to use◇Connect an inner cable to the throttle pipe.

◇Loosen the hex nut.
Tool to use

Open-end wrench, 14 mm

Open-end wrench, 8 mm

PY
◇Remove a top cap of carburetor, spring and throttle
valve.

Join together
here.

Throttle cable

More free
play
遊びが多く
なる

◇Attach a top cap, spring and throttle valve to the throttle
アジャスターcable.
Adjuster◇Fix the upper throttle housing with two screws.
※Tighten up the screw in the front first, and then the one
in the back.

Open-end wrench, 10 mm

六角ナッ
Hex nut ト

Notch

Throttle stopscrew

Less free play

◇Turning of the adjuster will adjust the free play.
About 5 mm

◇Unite the notch part of a throttle valve with a throttle stop

◇Unfasten two screws to remove an upper throttle
housing.

※In the case of a stock steering handle, align the joint on
the throttle housing with an “O” mark on the steering
handle.
◇Connect the throttle cable wiring.
◇Tighten up a hex nut.
Tool to use
Open-end wrench, 14 mm

13. Change of main jet.

screw, and attach in a carburetor.

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

Socketcap
screws 6x30

◇Hold the adjuster and tighten the hex nut.
Tool to use

GasketInsulator

Main jetGasket◇Detach an inner cable in the throttle cable from the◇Attach a gasket, an insulator, a gasket and an inlet pipewith socketcap screws 6x30 in this order.

throttle pipe.

Open-end wrench, 8 mm

Open-end wrench, 10 mm◇By snapping the throttle, check that the throttle valve
moves smoothly and without a hitch.
◇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 the boot.

16.Installation of air filter.

Tool to use

Float pin

Hex wrench, 5 mm
Caution: Apply the specified torque.

◇Unfasten four screws to remove the float chamber.
Tool to use

Torque: 10 N・m (1.0 kgf・m)

Cross tip screwdriver, (medium)※Bear in mind that the float pin is apt to come off.
◇Remove the main jet from the jet holder.
◇Install a provided main jet.
Tool to use◇Remove a stock throttle cable from the lower throttle
housing.

Flat tip screwdriver, (medium)◇Install the float chamber, and attach it to the carburetor◇Attach the band to the air filter, and fit it into the
carburetor. And fasten the band.

with four screws.
※To avoid interference with the crankcase, please cut
the drain section by nippers.

‑10‑

Dec./13/ 12

17.Installation of fuel tank.

19. Installation of drive sprocket.
(on the engine side)CO◇Fit a provided sprocket into the shaft.

◇Install the fuel tank onto the frame.

◇Install the fuel tank onto the frame with a bolt.
Tool to use
Offset box wrench, 10 mm

Caution: Apply the specified torque.

Clip◇Detach a clip from the drive chain.

Masterlink◇Attach a bolt and nut under the seat.
Tool to use◇Install a provided plate, and tighten two bolts loosely

Socket, 12mm

Link plate

Extension (short)
Offset box wrench, 12 mm

Torque: 12 N・m (1.2 kgf・m)

Caution: Apply the specified torque.
Torque: 22 N・m (2.2 kgf・m)◇Connect a fuel tube to the carburetor.

for now.

◇Detach a link plate and master link to remove the drive

PY
chain.
※Be sure to stop the engine while you are working.

◇Applying the rear brake, unfasten two bolts.
Tool to use

18. Installation of seat.

Socket, 10 mm
Extension (short)◇ Tighten two nuts on the rear shock absorber.
Tool to use
Offset box wrench, 14 mm
Caution: Apply the specified torque.
Torque: 34 N・m (3.5 kgf・m)◇Remove a plate.

◇Insert a seat-stay hook between two washers on therear shock absorber.

◇Pull out a stock sprocket from the shaft, and remove thechain.
◇Attach a side cover.

‑11‑

Dec./13/ 12

20．About a Driven (rear tire side) sprocket.
※With change of a drive sprocket, a driven sprocket is also changed and high gear-ization of a sprocket is performed.
※A driven sprocket changes with clutch form or tire size. Please make a lower table reference.
※The driven sprocket is not contained in the kit. Please purchase separately.
※When changing a driven sprocket, the circumference of a rear tire is removed. Vehicles are supported certainly in a racing stand etc.
and please float a rear wheel.

CO★A hyper-S stage kit A type recommendation sprocket(In the case of 65kg weight)

Tire size

Drivensprocket

Ratio

Centrifugal 3speed

１６

３０

１.８７

Stock manual

１５

２５

１.６７

Strengthening, special

１６

２５

１.５６

Stock

１６

２５

１.５６

Strengthening, special

１６

２８

１.７５

８
inc

１０
inc

Drive
sprocketClutch◇Install a change pedal.
Tool to use
Open-end wrench, 10 mm
Caution: Apply the specified torque.
Torque: 10 N・m (1.0 kgf・m)◇Check for slack in the bolts and the like fixed all the way from the engine to the suspension.

21．About a drive chain.

※If it changes into a recommendation sprocket from the sprocket of stock, the slack of a drive chain cannot be abolished only byadjustment. It is necessary to use a chain cutter etc. and to shorten a chain. Moreover, the length of a chain also changes with the lengthof a swing arm. Please make a lower table reference.

※It is surely suspending engine in the case of 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

−

−

−

◇Slack is checked for the bolts attached from the engine to the tire.

マスタ
Masterlink
ーリンク

１２ｃｍ Stretch １６ｃｍ Stretch
−

−

PY
−

−

９２

１００

９０

９８

９０

９８

９２

１００

23.Inspect and adjust the ignition timing.
◇If the ignition timing is off, the engine likely will malfunction seriously let alone fail toexhibit its original performance. Therefore, it is advisable to check and adjust the ignition◇Fit the master link from inside to connect the drive chain, and attach a link plate.

Link plate◇Turn on the fuel cock.

timing without fail.
If you cannot do the work yourself, we recommend that the work be done by your local
motorcycle dealer.

◇Attach a clip.
※Be sure to attach the clip with its end-gap in the opposite direction of driving.

Timing light◇Using a timing light (Item No. 00-01-009), check at the time of idling that the “F” markon the flywheel aligns with the alignment mark on the crankcase.
Alignment mark“F” mark

Driving
direction

Breaker-tightening
screw

Clip

Breakerplate◇Fully tighten the loosely-installed drive sprocket bolt.
Tool to use
Socket, 10 mm
Extension (short)
Caution: Apply the specified torque.
Torque: 12 N・m (1.2 kgf・m)◇Adjust the ignition timing by loosening the breaker-tightening screw and moving the
breaker plate a little bit at a time.
◇After the adjustment, rotate the crankshaft so that the point gap becomes the widest.
And measure the gap with a thickness gauge.
Point gap: 0.3 - 0.4 mm
In case the gap is outside the limits, replace the point.

22. Installation of crankcase left-side cover.
◇Install three bolts to hold a crankcase left-side cover.
Tool to use
Cross tip screwdriver (large)

Co.,Ltd.

Caution: Apply the specified torque.

3-5-16 Nishikiorihigashi Tondabayashi
Osaka Japan

Torque: 10 N・m (1.0 kgf・m)

TEL : 81-721-25-1357 FAX : 81-721-24-5059
URL : http://www.takegawa.co.jp‑12‑

Dec./13/ 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)

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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