φ 27 Two-Piece Front Fork Kit for 8 inch Wheel(for bar handle Fork width 174mm / Offset 60mm)
・Thank you for purchasing one of our TAKEGAWA products.
Please strictly follow the instructions to install and use the kit.
・Before installing the kit, please be sure to check the kit contents.
If you have any questions about the kit, please contact your local TAKEGAWA
dealer.
◎ Please note: Illustrations and photos may vary from actual
hardware.

Item Nos：０６−０１−０２１１ (With fender)：０６−０１−０２１２ (Without fender)
Fitting models and frame Nos:Monkey：Z50J-1300017〜：AB27-1000001 〜
Monkey (FI) ：AB27-1900001 〜

Features○ Fork width 174mm, Offset 60mm.
○ 60mm offset can extend the wheelbase and increase the stability.
○ Machined and lightweight triple clamp.
○ Buffed and polished finish.
○ Included handle bar holder○ Anodized stem nut.
○ Included steering lock bracket.

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 product not in conformity with the instructionsin this Instruction Manual.
◎ If you make modifications to any product supplied here, we shall be held free from any guarantee of the product.
◎ We do not have any information or service data on the combination of our products and other manufacturer’s products.
◎ Please do the disassembly and installation correctly, referring to a Honda’s service manual for the Monkey or Gorilla.
◎ This Kit is for 8inch wheels only.
◎ If you use our 8-inch aluminum wheel, please separately purchase 6-mm wheel spacers.
◎ A headlight bracket, turn-signal bracket and a handlebar are not included in this Kit. Please purchase them separately.
◎ Please use TAKEGAWA aluminum headlight bracket(09-03-007, 008 or 09-03-07S).
◎ The following handlebars in TAKEGAWA are applicable.: Racing up, middle up, semi up, and BAT.

▽▽

▽

▽

▽

▽

◎ The following TAKEGAWA-made parts are required for the use of this product:
A mirror with a 10mm thread (in packs of one)
Oval slide-type mirror (06-01-110)
NC31-type mirror (06-01-111)
Rectangular slide type mirror (06-01-112)
Mini mirror (right-hand mirror only) (06-01-113)◎ The brake cable included in this Kit cannot be installed onto a stock brake lever. Therefore, please separately purchase our brake lever.
Our products:
Quick lever assembly (06-08-3005)
Brake lever (06-08-300)◎ It is necessary to remove a stock throttle housing (integrated with a brake lever). Therefore, either our high throttle set or a Honda’s genuine part isneeded, which are compatible with the installed carburetor
In case our carburetor kit of PD22, PE24, VM26 or PE28 is used:High throttle set (cable length: 810 mm) (09-02-0221, 09-02-0230 or -0231)
High throttle set (cable length: 700 mm) (09-02-0222, 09-02-0232 or -0233)
In case a stock carburetor, or our carburetor kit of PC18, PC20, PD22, or PE24 is used:(In the case of PD22 or PE24, a high throttle can be used.)
Honda genuine parts
Throttle housing (1 pc) (53168-166-000)
Throttle housing (1 pc) (53167-GE4-000)
Pan screw, 5 x 22 (2 pcs) (93500-05022-0G)※ A genuine throttle cable cannot be used on a motorcycle with a frame No. Z50J-130017 ~ 1510400.
If a stock carburetor is installed, a cable complete and throttle of 17910-165-640 are required.
◎ In installing this product onto a motorcycle with a frame No. Z50J-1300017 ~ 1510400, the following parts are additionally needed.
For a centrifugal clutch motorcycle:
Combination switch assembly (02-01-015)
For a manual clutch motorcycle:
Clutch lever & combination switch assembly (02-01-016)

CAUTION

The following show the envisioned possibility of injuries to human bodies and property damage as a result of disregarding thefollowing cautions.

・Before starting installation, make sure that your bike is secure on level ground.
・Always use a torque wrench to tighten bolts and nuts securely to the specified torque to avoid these parts getting damaged or loose.
・Prepare appropriate tools and work properly to avoid the breakage of parts or injuries.
・When unfastening a fork top bolt, be careful the fork top bolt can fly loose by fork spring force, causing injury.
‑1‑Dec./09/ 10

The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding theWARNING following warnings.

・Those who are technically unskilled or inexperienced are required not to do the work.
(Improper installation because of insufficient skill or knowledge could lead to parts breakage and subsequently to overturning or accidents.)
・Before riding, always check every hardware like screws for slack. When you notice something abnormal 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.)
・Do not let the oil and grease adhere to the brake lining or brake shoes. If oil or grease adheres to them, change the brake shoe, and degrease
the brake lining. (Otherwise, the adherence may lead to an accident.)
・Get the brakes installed by a skilled mechanic at facilities with special instruments and tools.
(Otherwise, the wrong installation will cause accidents.)◎ 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.

Kit consists of:
１０６―０２―００１７０６―０８―３０３０６―０２―１００２ ０６―０２―１００４ ０６―０２―１００５１４ １８６３２２０４２２５７８１０１１９ １９No.

Part Name

Repair Part Item No.

２７２３ ２４２５１５Qty

１６ １７２６１３
１２２１

in packs ofNo.

1

Left-side front fork assembly

151508-GEF-T01

1

15

2

Right-side front fork assembly

151408-GEF-T01

13Fork top bridge

14Upper handle holder

254411-165-T00

5Lower handle holder2Part NameQty

Repair Part Item No.

in packs ofFront brake cable (750mm)

145451-165-T00

1＊16Hex bolt, 5 x 20

400-00-0113

517

Flange bolt, 6 x 15

200-00-0114

4118

Flange bolt, 6 x 25

100-00-0115

554412-165-T00

119Socket cap screw, 6 x 20

200-00-0043

106Steering stem COMP.

120

Socket cap screw, 6 x 12

200-00-0116

67

Steering lock bracket

153601-GEF-T00

121

Socket cap screw, 6 x 50

400-00-0044

38Stem nut

154303-165-T00

122Socket cap screw, 8 x 25

200-00-0075

49Stem nut washer

190503-165-T00

1＊23

Plain washer, 5 mm

400-00-0118

10＊10

Front fender161100-181-T00

124

Plain washer, 6 mm

100-00-0086

10＊11

Front fender bracket

261102-181-T00

125Sub-cord

137600-KCZ-T00

112

Front axle shaft

144301-124-T00

126

Hex wrench, 5 mm

113

Front brake panel

145101-165-T00A

127

Hex wrench, 6 mm

114

Brake arm

1

※ Item numbers marked with an asterisk is not included in the Kit of 06-01-0212.
※ Please order repair parts with the Repair Part Item No. Without the repair part item NO., we may not be able to accept your orders.
Some parts are only available as a set. In this case, please order them with the set number.

〜 Installation Instructions 〜Disassembly:
１．Loosen an axle nut on the front wheel.
２．Before starting the work, stand your bikesecurely on a rear maintenance stand placedon a suitable pedestal under the engine.
※Choose a pedestal of a height so the front
wheel is just off the ground.
３． Remove brake wires on the wheel side.
４．Unfasten a pan screw from the throttle
housing to remove the throttle housing andthrottle pipe.
５．Unfasten a pan screw from the turn-signal
switch to remove the switch.
６．Unfasten right and left bolts on the headlightto remove the headlight.

７．Remove a horn and turn signals.
８．Pull out an axle nut and axle shaft to remove
the front wheel.
９．Unfasten a nut on the lower handle holder
at the back of the top bridge, and demount asteering handle assembly.
１０．Unfasten a fork bolt, stem nut and washer toremove the top bridge.
１１．Remove a top thread and then a fork
assembly.
※ Be careful not to lose bearing balls.

‑2‑

１２．Remove a handle lock from a stock
steering stem, which please attach to asteering lock bracket.
Caution: Apply the specified torque.
Torque: 9 N･m (0.9 kgf･m)

Dec./09/ 10

Assembly:
１３．Install the steering lock bracket to thesteering stem with a 6x12 socket cap
screw.
Caution: Apply the specified torque.
Torque: 12 N･m (1.2 kgf･m)

１６．Fit the steering stem into the head pipe, andhand tighten the top thread until it stops. Moveit several times to the right and left so thebearing may fit right. Give it 1/8 turns
backward and check that it moves smoothly
and without rattling.

１９．Routing the wire harness in the same way
as the stock one, fit the top bridge into thefront fork and stem shaft. And attach thestem washer and tighten the stem nut tothe specified torque.

１７．Fit the front fork to the steering stem with thewhirl stop on the axle holder on the rightviewed in the direction of travel. And tighten
an 8x20 steering-stem split clamp bolt loosely
for the moment.

２０．Loosen the split clamp bolt on the steeringstem, and adjust the right and left innertubes evenly.
※Protrude the inner tube about 30 mm sothe caster angles become the same as thestock caster angles.

Caution: Apply the specified torque.
Torque: 59 N･m (6.0 kgf･m)

１４．Remove a bottom cone race on thesteering stem with a punch driver or achisel, and detach a dust seal and dust
seal washer.
And attach the dust seal washer, dust seal,and bottom cone race to the duralumin stem
shaft.

Bottom cone race

Dust seal
Dust seal washer
１５．Apply grease to the top cone race andbottom cone race, and attach the bearing
to the steering stem and head pipe, andthen the top cone race to the head pipe.
※In case the balls are not set in the bearing
housing, then install 21 balls each to thebottom cone race and top cone race.
Before applying grease, first wash thebearings with a solvent. Be careful not to
let the dirt adhere to the bearings.

２１．Tighten the split clamp bolt on the steeringstem to the specified torque.
Caution: Apply the specified torque.
Torque: 26 N･m (2.7 kgf･m)

Whirl stop
１８．Fit the front fork on the left side in the same
way as you fitted it on the right side.
※ Protruding “Wide” should be installedoutside.
※ In case a front-fork clamp-type headlightbracket is used, fit the headlight bracket into
the front fork.

２２．
Tighten a 6x20 split clamp bolt on the top
bridge to the specified torque.
Caution: Apply the specified torque.
Torque: 12 N･m (1.2 kgf･m)
２３．Set a steering handle pipe into the handle
holder and install it to the top bridge. Tightena 6x50 socket cap screw on the handle
holder to the specified torque.
Caution: Apply the specified torque.
Torque: 12 N･m (1.2 kgf･m)※ Tighten the handle holders to be spaced
equally in the front and at the back.

INNarrow‑3‑OUT
WideDec./09/ 10

２４．Install a throttle pipe, throttle housing, turnsignal switch, and left-hand grip to thehandlebar.
Caution: Apply the specified torque.
Torque:4 N･m (0.4 kgf･m)（０６−０１−０２１２）
Install the stock front fender and bolt.
※If you install the horn onto the steering stem,
using a stock front fender, place the horn inbetween the front fender and steering stem.
Install a washer of about 1.5 mm in thickness
in another clearance between front fenderand steering stem, and tighten it with a 6x15
flange bolt.

２９．Install the removed front frame with aprovided axle shaft in the reverse order of
its removal.

Caution: Apply the specified torque.
Torque: 12 N･m (1.2 kgf･m)
３０．Replace the brake cable with the providedone.
３１．
Route the brake cable just as the stock one
was routed, and attach it to the brake panel.
３２．(If your front fender is a stock one,move on to 33. below.)

Stockfender
Horn
２５．Install a horn. (The photo below shows thehorn installed onto the steering stem.)※If you install the horn to the steering stem,
fold back the bracket as shown in the photo
below, and fix it by tightening up a 6x15
flange bolt.
Caution: Apply the specified torque.
Torque:12 N･m (1.2 kgf･m)

Washer

２７．Unfasten a nut which is holding both the hubon the front wheel and the wheel. And fix thehub with the air valve on the left.

Tighten up the flange cap screw holding
the wheel and hub.
Caution: Apply the specified torque.
Torque:5 N･m (0.5 kgf･m)

Caution: Apply the specified torque.
Torque: 25 N･m (2.5 kgf･m)※ If our 8inch aluminum wheel is used, the air
valve should be on the right side. And fix thewheel spacer of 6mm in thickness between
the hub and wheel.
３３．Install the headlight.
Caution: Apply the specified torque.
Torque:25 N･m (2.5 kgf･m)
３４．Install turn signals.
２８．Remove the brake shoe and front brake camfrom the stock brake panel, which pleaseattach to our brake panel. And install our brakearm onto the front brake cam with a 6x25
flange bolt.

mm
About 40

Caution: Apply the specified torque.
Torque: 12 N･m (1.2 kgf･m)２６．（ ０ ６ − ０ １ − ０ ２ １ １ ）As shown in the photo below, attach afront fender and bracket with hex bolts
and tighten it temporarily.

※Wipe off the old grease on the front brakecam and apply new grease to it.
※Installing this kit with a stock brake lever, punchmarks on the front brake cam and on the brakearm should be put off one-pitchcounterclockwise from each other. So twopunch marks will not align.

Caution: Apply the specified torque.
Torque:12 N･m (1.2 kgf･m)
３５．Remove the maintenance stand and theJack from the vehicle and stand thevehicle on the level ground securely.
３６．Tighten the axle nut.
Caution: Apply the specified torque.
Torque:62 N・m (6.3 kgf・m)

5x20 hex bolt

Bracket

5mm plain washer‑4‑Dec./09/ 10

How to change front fork oil:
１．Remove the fork top bolt.
２．Loosen an axle nut on the front wheel, and remove only a nut.
３．Before starting the work, stand your vehicle securely on a rear maintenance stand placed on a Jack under the engine.
※ The work will be easier at the height obtained when your vehicle stands with the front fork stretched to the fullest extent.
４．Pull out the axle shaft to remove the front wheel.
５．Unfasten the split clamp bolts on the top bridge and stem to remove the fork.
６．Unfasten the top bolt, being careful not to let it spring out. Prepare an oil pan, and stand the fork upside down to pull out the spring.
７．Expand and compress the inner tube to drain the fork oil. (Leave the inner tube facing downwards for a few minutes.)
８．Stand the front fork to add fork oil.
Fork oil : No. 20
Fork oil amount: 68 cc per fork
９．Wipe off oil on the fork spring, and put in the spring with the narrower-pitched portion facing downwards. Attach the top bolt and tighten it loosely
for the moment.
１０．Install the front fork to the stem and top bridge, and tighten the split clamp bolt loosely for now.
１１．Tighten the top bolt to the specified torque.
Caution: Apply the specified torque.
Torque: 20 〜 24 N・m (2.0 〜 2.5 kgf・m)
１２．Tighten the split clamp bolts on the steering stem and top bridge to the specified torque.
Caution: Apply the specified torque.
Torque: 26 N・m (2.7 kgf・m) for steering stem,
12 N・m (1.2 kgf・m) for top bridge
１３．Install the front wheel in the reverse order of disassembly.
Caution: Apply the specified torque.
Torque: 62 N・m (6.3 kgf・m) for axle nutCo.,Ltd.
3-5-16 Nishikiorihigashi Tondabayashi Osaka Japan
TEL : 81-721-25-1357 FAX : 81-721-24-5059
URL : http://www.takegawa.co.jp‑5‑Dec./09/ 10