Hyper S-Stage KIT Instruction manual
Product number 01-05-0238 (A-TYPE)

Adaptation model Monkey / Gorilla (Z50J-1300017 ～ 1510400)

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

Caution about FuelAs this S-Stage Kit is so designed to achieve a higher compression ratio than stock engines, always use the high-octane gasoline.
In case regular gasoline is used, unusual combustion will take place, and the engine cannot achieve its original performance.
Moreover, it is highly likely that the piston will be damaged, leading to a serious failure of the motorcycle. Before installing thisKit, 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 high-octane gasoline.

Caution about Spark PlugCOBe 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.

Caution 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.

☆ Please read carefully before use ☆

◎ We do not take any responsibility for any accident or damage whatsoever arising from the use of the Kit not in conformity with the
instructions in this Instruction Manual.
◎ We shall be held free from any kind of warranty whatsoever of products other than this product if the glitch takes place on the otherproducts than this one after the installation and use of this product.
◎ If you make modifications to any product supplied here, 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 compatible models with the specified 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, thisInstruction Manual and genuine service manuals are prepared for those who have acquired basic skills and knowledge. We, therefore, recommend
those who are technically inexperienced or without sufficient tools to ask a technically-reliable specialist shop for the installation work.
◎ Bolts, nuts, and dowel pins will be reused. However, be sure not to use the worn-down or severely-damaged ones, which please do
replace with new ones.
◎ If you use a stock carburetor, do not remove an air cleaner box or air cleaner elements. If you change the carburetors, please do
the setting to match various conditions. Disregarding 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.
CautionPY

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

■ Always try to drive your motorcycle at legal speed, abiding by the laws.
■ Work only when the engine and muffler are cool. (Otherwise, you will get burned.)■ Do the installation with right tools. (Otherwise, breakage of parts or injuries to you may take place.)■ Always use a torque wrench to screw bolts and nuts tight and securely to the specified torque.
(Otherwise, these parts may get damaged or fall off, resulting in accidents.)■ As some products and frames have sharp edges or protruding portions, please work with your hands protected.
(Otherwise, you will suffer injuries.)■ Before riding, always check every hardware like screws for slack. If you find slack ones, screw them securely up to the specified torque.
(Otherwise, improper tightening may cause parts to come off.)※ As for the cylinder head among others, please be sure to tighten it up to the specified torque.
■ Always use new gaskets and packings. And check those parts, to be reused, for wear and damage. If you find worn or damaged parts,
replace them with new ones.
Warning

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

■ Always start the engine in a well-ventilated place, and do not turn on the engine in an airtight place.
(Otherwise, you will suffer from carbon monoxide poisoning.)■ When you notice something unusual with your motorcycle while riding, immediately stop riding and park your motorcycle in a safe place
to check what has gone wrong. (Otherwise, the malfunction could lead to accidents.)■ Before doing work, make sure your motorcycle is secure on level ground for safety's sake.
(Otherwise, your motorcycle could overturn and injure you while you are working.)■ Carry out inspection and maintenance of your motorcycle correctly according to the instructions and guidelines in the instruction
and service manuals.(Improper inspection or maintenance could lead to accidents.)■ If you find damaged parts when inspecting or performing maintenance of your motorcycle, do not use these parts any longer, and replacethem with new ones. (The continued use of these damaged parts as they are could lead to accidents.)■ As gasoline is highly flammable, never place it close to fire. Make sure that nothing flammable is near the gasoline. Since vaporized
accumulation of gasoline is at high risk of explosion, work in a well-ventilated place. (Otherwise it may cause a fire.)◎ Please note. Performance up, the design change, the product and the price in the cost up, etc. are subject to change without notice.
◎ Please be informed that we shall be held harmless against any claim against us whatsoever arising out of use of the products in
racing and the like.
◎ Keep this manual stored until this product is discarded.
CONTACT Address : 3-5-16 Nishikiorihigashi Tondabayashi Osaka JAPANTEL: +81-721-25-1357 FAX:+81-721-24-5059 e-mail:english@takegawa.co.jp URL http://www.takegawa.co.jp
Please contact with your name and country name provided. (Only English please)2022.10.6

01-05-0238

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Product content

①

③ ④

⑤

⑥

⑦

⑧

⑨

②
⑩
⑰
⑮

⑪

⑫

⑬

4
5
6
7
8
9
10
11
12
13

CO
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

㉖

㉒

⑲

㉔
㉓

⑭

NumberProduct content
1
Piston2
Piston ring set
3

⑱

⑯

⑳

㉑
㉕

Quantity
Item Number
100-00-1204
1
01-15-014
00-01-0091
1(with ④ clip)
200-01-0003
1
01-01-0241H
100-01-0067 (2 pcs)
100-00-1147
100-01-0156 (2 pcs)
100-00-1181
100-01-0158 (2 pcs)
200-01-0034 (4 pcs)
100-01-0064 (2 pcs)
100-01-0066 (2 pcs)

NumberProduct content
14 Camshaft
15 Carburetor ASSY.
16 Intake manifold
17 Air filter (with band)
18 Carburetor gasket
19 Inlet pipe gasket
20 Socket cap screw, 6x20
21 Socket cap screw, 6x25
22 Throttle cable, 710mm
23 Spark plug, CR8HSA
Drive sprocket
24(with plate) 15T
25 Main jet, #85
26 Mark set

Quantity
1
1
1
1
1
1
2
2
1
1

PY

Item Number
01-08-0068
03-03-0061
00-00-1484
03-01-104
00-03-0417
00-01-0159 (2 pcs)
00-00-0721 (5 pcs)
00-00-0722 (5 pcs)
09-02-0071
00-00-2377

1

02-05-041

1
1

00-03-0041※ Please order in the repair parts are always repair part number. If it is not the part number order, you may not be able to order.
Please be forewarned. It should be noted, In the case of parts that can not be separately shipment, please order a set part number.

Tools to use for the installation:1

9 10 11

14

12

2

13

3

15

4

16
17

5
18
6

19
20

7
8
21

22

1
2
3
4
5
6
7
8
9
10
11
12
13

Torque wrench
Open-end wrench 8-10mm
Open-end wrench 10-12mm
Open-end wrench 12-14mm
Offset box wrench 8- 9mm
Offset box wrench 10-12mm
Offset box wrench 14-17mm
Ratchet handle
Socket 8mm
Socket 10mm
Socket 12mm
Extension bar (short)
Extension bar (medium)

14
15
16
17
18
19
20
21
22

Spark plug wrench set(in-vehicle tool set）
Cross tip screwdriver (large)
Flat tip screwdriver (medium)
Fine-shaft flat tip screwdriver
Hex wrench, 5mm
Needle-nose plier
Plastic hammer
Thickness gauge
Cutter knife or scraper
Wire
Waste cloth or rag
Engine oil

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

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

Dowel bolt, 5 MM

Cam sprocket

Cam shaft COMP.

PY

Tappet adjusting hole cap

O-ring, 30 MM

Cylinder head cover gasket

Hex nut, 6 MM

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

Cylinder head gasket

Inlet pipe gasket

O-ring, 30 MM

Tappet adjusting hole cap※3 Spark plug

※2

※3

※2

※1

Bolt, 6 MM

Cam chain guide roller COMP.

※1 Dowel pin, 8x14

Bolt, 6 MM

Washer, 8 MM

Guide roller bolt

※1 Dowel pin, 8x12

Cylinder gasket

Rubber packing, 16 MM

PistonPiston pin

Piston pin circlip

Piston ring set

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

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

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

COCap nut, 6 MM

Sealing washer, 6 MM

Cylinder head cover

Valve rocker arm

Tappet adjusting screw

Tappet adjusting nut

Valve rocker arm shaft

Flange bolt, 6x20

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

Right-side cylinder head side cover

Right-side cylinder headside cover gasket

Part Names

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

● Removal of standardparts◇ Unfasten a bolt on the
air-cleaner stay.

○ Remove a fuel tank.
◇ Turn off a fuel cock.

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

○ Remove a seat.
◇ Remove a side cover.

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

CO◇ Loosen a nut under the seat
to unfasten a bolt.

◇ Loosen two nuts on the rearshock absorber.

◇ Unfasten a bolt holding thefuel tank to the frame.

◇ Unfasten two bolts attachingan inlet pipe to the cylinder
head to remove the inlet pipe,
carburetor, and air cleaner.

◇ Detach two collars of theflange and then detach the
muffler from the motorcycle bypulling it outwards.

PY◇ Move the wire harness so itsits under the frame.

○ Remove a front fender.

Clamp

Wire harness◇ Dismantle a fuel tank by pullingit backwards.

◇ Remove two hex bolts on thereverse side of the front
fender by turning themcounterclockwise.

○ Remove a muffler.

◇ Remove two nuts on the exhaust
pipe by turning themcounterclockwise.

○ Remove a spark plug.

◇ Dismantle a seat by pullingit backwards.

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

2022.10.6

01-05-0238◇ Remove the hex nut securing
the muffler by turning it
counterclockwise.

/12◇ Detach a plug cap from theplug by pulling it out.
Be sure to hold the cap inpulling it out.
◇ With an in-vehicle tool of a
spark plug wrench, turn theplug counterclockwise toremove it.

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

○ Remove a cylinder-head
left-side cover.
◇ The left-side cover will come
off when a hex bolt in the
middle of the cylinder-headright-side cover is removed.
（In case the left-side coverdoes not come off by so doing,screw a few threads of thehex bolt,and strike the bolt
head with a hammer lightly.
Then the bolt will come off.）○ Remove a cam sprocket.
◇ Turn the flywheel counterclockwise
so a "T” mark on the flywheel
and“O” mark on the cam
sprocket align with each notch.

◇ Turn counterclockwise theguide roller bolt on the cylinder
and the side bolt between thecylinder and the crankcase toloosen these bolts.

◇ Pressing the front tire,remove the cylinder head.
◇ Be sure to save two dowelpins for use later.

Guide roller bolt
Notch“O” mark stamped here
Side bolt

CO○ Remove cylinder-headcover.

Notch○ Remove the cylinder.
◇ Remove the loosened guide rollerbolt and cylinder side boltby turning them counterclockwise.

◇ Remove four nuts, which holdthe cylinder head cover,byturning them alternately,
diagonally, and counterclockwise.
◇ Remove four washers beneaththe nuts.

Flywheel◇ Holding the flywheel, remove
three hex bolts on the cam
sprocket by turning themcounterclockwise.

○ Remove a crankcase leftside cover.
◇ Unfasten a hex bolt on theshift pedal and remove theshift pedal by turning it
counterclockwise.

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

◇ Remove three screws which are
holding a crankcase left side
cover by turning themcounterclockwise.

◇ Remove the cylinder by pulling
it out. (If it is hard to pull
it out, hit the cylinder lightly
with a plastic hammer.)◇ Remove the head cover. (If it
does not come off easily,strikeit lightly with a plastic hammer,
and it will come off.) If somegaskets remain on the cylinder
head, wipe them off completely
with a scraper or a cutter.

PY○ Remove cylinder head.

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

○ Remove cylinder-headside bolt.
○ Remove two tappet caps.
◇ Remove two tappet caps by
turning them counterclockwise.

2022.10.6◇ Remove the cylinder-head sidebolt, which holds the cylinder
head and cylinder, by turning
it counter clockwise.

01-05-0238◇ Let air out of a front tire.
(At the press of the valve withsomething like a tip of a crossslot screwdriver, the tire will
deflate. Continue pressing ittill the whoosh of air cannot
be heard any longer.)◇ Remove the cylinder head fromthe cylinder by pulling thehead away from the cylinder.
(If it does not come off easily,
strike the cylinder head lightly
with a plastic hammer, and it
will come off. )/12◇ While removing the cylinder,
the cam chain guide roller will
come out, which please remove.

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

○ Remove the piston.
◇ Plug in a waste cloth so as
never to get the dust orcomponent in the cylinder holein the crankcase or cam chain.

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

◇ 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.

◇ Cut off the gasket squeezing out
at the section pointed by a finger
as shown in the above picture.

◇ Attach the oil ring expanders.

● Installation of
S-Stage Kit○ Fabrication of piston.
◇ Fix a supplied piston pin circlip
securely to the grooves in thecirclip on one side of the piston.
Be sure to set the circlip so its
ring-end gap is not on the notch.

Piston circlip◇ Remove the piston pin in the
direction where the piston
circlip is not attached.
You can easily remove thepiston pin by pressing it witha flat tip screwdriver from thedirection where a piston pin
circlip is attached.

◎ Cautions for installing
aluminum cylinderCO◇ Remove the piston.

◇ In fixing the cylinder onto the
crankcase, in some cases there
is interference in the sleevehole in the crankcase mating
surface, circled portions, theshaded area of the cylinder
sleeve, and inside of the
crankcase, because the right andleft crank cases are not meshingcorrectly. Since the continued
use of such crankcase will leadto sleeve deformation and engine
troubles, do not fail to checkthe crankcase for theinterference, and correct theinterference,if any.
The difficulty level of the work
is quite high. So, you may feellike having come close to theprofessional level if you havesuccessfully completed the job.

◎ Tips on how to fix theinterference○ Remove cylinder gasket,
rubber packing and dowelpin.

◇ In case you cannot remove all
the gaskets completely,rasp
or wipe them off with a scraperor something else,exercising
great caution not to scratch
the crankcase.
In case the crankcase center
gaskets squeeze out into thecylinder base or into thecylinder hole, cut them off.
Never let any dirt, dust or
hardware into the crankcase.

Left
side
◇ You can rather easily install
the piston pin circlip by pressing
it with a screwdriver, but taking
care not to scratch the pistonwith the screwdriver.
◇ Apply engine oil to thepiston-ring grooves, and fix pistonrings in the order of an oil ring
expander,lower oil ring side rail,
upper oil ring side rail, second
ring,and top ring.
◇ Referring to the figure below,
mesh the each piston ring-end
gap with each other.
Mark

Mark

Top ring◇ Attach the top ring.

Second ring

Side
rail

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

After being fixed

Stamped on the top ringand the second ring.

Cylinder gasket

SleeveInterfering portion

Top ring(silver side)

CylinderSecond ring
(Black)Side rail

PistonExpanderPay attention to the crosssection as we
2022.10.6◇ Attach the second ring.

ExpanderLeft side
crank case

Rubber packing◇ Attach the upper oil ringside rail.

PY

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

◇ Attach the lower oil ringside rail.

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

◇ Install with the“IN”mark on
the piston head facing theintake side.

◇ Check that two dowel pins arepresent.

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

Intake sideIN

◇ It will also be an easy way
of installing the piston toinsert the piston pin a third
into the piston.

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

CO◇ Fix a supplied piston pin
circlip securely to the grooves
on circlip.
◇ You can rather easily install
the piston pin circlip bypressing it with a screwdriver,
but taking care not to scratch
the piston with the screwdriver.
※ Do the work carefully as, insome cases, the circlip comes
off flying while you are pressing
it inside. So, wear protective
eyeglasses for your eyes lestit should get into your eyes.

◇ Install the supplied camshaft
in the reverse order of removal.
Apply clean engine oil to thecam top and journal of thecamshaft.
Even if you cannot easily fix
the camshaft, fix it manually
without striking it with ahammer.

◇ Tighten the tappet screw on
the rocker arm by turning it
clockwise.
◇ Install the guide roller bolt.
(Tighten it only finger tight at
this point.)◇ Pressing the tire, install thecylinder.

○ Installation of cylinder
head.

PY
◇ Install a cylinder side bolt.
(Tighten it only finger tight at
this point.)◇ Install the cylinder, by pressing
it inch by inch with fingers,being
careful not to move the piston
ring-end gaps out of alignment.

◇ With thinner, degrease thecylinder head surface andupper surface of the cylinder.
◇ Fix two dowel pins into thecylinder.

○ Change of camshaft.

◇ Remove the stuffed waste cloth.

○ Installation of cylinder. ◇ Once the rings have been fixed into
◇ Degrease the gasket-mounting
surfaces of the cylinder andcrankcase.
◇ Install the cylinder gaskets
and rubber packing.

the cylinder, pass the cam chain
through the cylinder, and fix
the cylinder into the crankcase.

◇ Pulling the cam chain, fix theguide roller.

2022.10.6

01-05-0238◇ Detach tappet nuts and boltson the rocker arm assembled
into the cylinder head.
◇ At the time the tappet nuts areloosened, detach the tappet
bolts and nuts together.

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

/12◇ Attach a head gasket.

◇ Pressing the tire with a hand,
fit the cylinder head into thestud bolts.
◇ Passing the cam chain throughthe cylinder head,install the
cam chain.

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

◇ Hold the cam chain by sticking
the screwdriver through thecam chain into a middle holeon the camshaft so the cam
chain will not fall into thecylinder.

◇ Tighten up the head nuts evenly.
(In case a torque wrench is notavailable, tighten themdiagonally,securely and little
by little.)○ Installation of cam
sprocket.
◇ Align the "T" mark on the flywheelwith the notch on the crankcase.
Notch

Note: Be sure that you protect
specified torque.
Head nut

Torque：12N・m（1.2kgf・m）

CO◇ Attach the cylinder-headcover gasket and head cover.

◇ Attach a head-side bolt.
Tighten fully the guide roller
bolts and the cylinder sidebolts which were tightened
temporarily.

◇ The arrow should face downward.

◇ Turn the cam shaft hole to thenotch on the cylinder head.
This arrangement places the cam
shaft at TDC (Top Dead Center)on the compression stroke.
※ In installing the optional cam,please refer to its instruction
manual.

○ Adjust the cam chain.
◆ When adjusted the cam chain,please perform "Inspection
and adjustment of ignition
timing" as well.
◇ Loosen the 8mm nut and theadjust bolt A, then the cam
chain will be adjusted
automatically by the spring.
But in case the cam chain is
not stretched tight, keep theloosened adjust bolt A as itis, and gradually tighten theadjust bolt B so that the cam
sprocket and cam chain fit
together even when the
flywheel is turned.
◇ Tighten the adjust bolt A,
and then 8mm nut.

Hole

Note: Be sure that you protect
specified torque.
Guide roller bolt

Torque：10N・m（1.0kgf・m）
Notch

lower and upper side bolt

Torque：10N・m（1.0kgf・m）

Beware of this positioning mark

◇ Install the head-cover washers
and the nuts.
(Attach a copper washer andthree iron washers at the lower
left,and a hex nut and three
cap nuts at the lower right,
when the engine viewed fromthe front.)

AdjustAdjust◇ After fixing the cam sprocket,
bolt Bbolt A
attach the bolt. While attaching
the cam sprocket to the cam chain,install the cam chain so the“O”
mark on the cam sprocket and thenotch on the cylinder head mesh ○ Adjust valve timing andtogether. Then, attach the camtappet.
sprocket to the camshaft.
◇Turn the flywheel until the“O”◇ Install the camshaft washer.
mark on the camshaft and the“T”mark on the flywheel meshwith each notch. Though the
flywheel will not stop right at
the required postion because
the magnet repels each other,
it is all right if“O”and“T”
marks mesh with each notch at
the same time after fixing the
cam sprocket.

PY

Notch

◇ Holding the flywheel, tighten
up three cam sprocket bolts.

Note: Be sure that you protect
specified torque.
Sprocket bolt

Torque：9N・m（0.9kgf・m）

Copper washer

Stamped“O”markCylinder head side
Notch

Flywheel sideHex nut

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

◇ While tightening a rocker arm’s
tappet screw, tighten the tappet
nut to the extent that a 0.05mm
thickness gauge,placed between
the tappet screw and the valve
stem end, can be pulled out
with only a little resistance.
If you have no idea of theproper resistance in pullingout the 0.05mm thickness gauge,then prepare a 0.07mm and 0.03mm
thickness gauges. When the 0.07mm
gauge won’t go in between thespace but the 0.03mm gauge goesin quite loosely, this meansthat roughly 0.05mm clearance
is secured. Set the space at
0.05 mm both for intake andexhaust.

◇ Install two tappet caps.

○ Installation of spark plug. ◇ Install loosely for now a hex

Note: Be sure that you protect
specified torque.
Tappet cap◇ Install a provided plug with
in-vehicle tools or spark plug
wrench.

Torque：12N・m（1.2kgf・m）

CO◇ Attach a plug cap to the plug.

○ Installation of stock
muffler.

○ Installation of cylinderhead left-side cover.

Adjust screw

Note: Be sure that you protect
specified torque.
Hex bolt

Torque：26N・m（2.7kgf・m）

Torque：11N・m（1.1kgf・m）

Valve clearance(intake side)

Valve clearance(exhaust side)

Note: Be sure that you protect
specified torque.
Plugbolt to hold the muffler.

◇ In installing the muffler,routethe tail pipe inside the rearshock absorber first, and then
set the flange to be roughly
under the exhaust port.

Valve stem

○ Installation of front
fender.
◇ Fasten two hex bolts on thereverse side of the front fender.
Note: Be sure that you protect
specified torque.
Hex bolt

Torque：10N・m（1.0kgf・m）◇ Attach a cylinder-head left-side
cover gasket and left-side cover.
(Set the anti-rotation stopper ofthe left-side cover to prevent thecover from turning to the rightwhen the bolt is being tightened.)

Thickness gauge◇ Tighten up three portions
which have just been loosely
tightened for the moment.

PY◇ Install two flange collars
squeezing the exhaust pipe.

◇ Pump a tire.

○ Installation of throttle
cables.
◇ Disconnect wiring on thestock throttle cable.
◇ Loosen the hex nut.

◇ Tighten two nuts on the exhaustpipe, loosely for the moment.

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

Note: Be sure that you protect
specified torque.

Nut

Torque：10N・m（1.0kgf・m）◇ Tighten a hex bolt on the rightside of the cylinder head asshown by an arrow.

◇ Unfasten two screws to remove
an upper throttle housing.

Note: Be sure that you protect
specified torque.
Hex bolt

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

◇ Attach a nut on the reverse sideof the muffler loosely for now.
Note: Be sure that you protect
specified torque.
Nut

Torque：10N・m（1.0kgf・m）

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/12◇ Detach an inner cable in thethrottle cable from the throttle
pipe.

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

◇ Rasp the shaded part of thethrottle pipe as indicated in
the figure below.

○ Change of main jet.

○ Installation of carburetor. ◇ Fix the top cap onto the◇ Unfasten two screws to remove
the float chamber.

◇ Put the inlet pipe gasket
between the intake manifold andcylinder head, and fix the gasket
with two 6x25 socket cap screws.

Throttle
pipe

Float chamber
Rasp thisportionthrottle cable, and fix thespring, and install the throttle
valve onto the inner cable.

Note: Be sure that you protect
specified torque.
Socket cap screw◇ Remove a stock throttle cablefrom the lower throttle housing.

Torque：12N・m（1.2kgf・m）
Screw※ Bear in mind that the float pin
is apt to come off.

CO

Float pin

Inlet pipe gasket◇ Attach a provided throttle
cable to the lower throttle
housing.

◇ Put the carburetor gasket
between carburetor and intake
manifold, and fix the gasket
with two 6x20 socket cap screws.

◇ Remove the main jet from thejet holder.
Jet holder

Note: Be sure that you protect
specified torque.
Socket cap screw

Main jet◇ Connect the inner cable tothe throttle pipe.

Torque：12N・m（1.2kgf・m）◇ Align the notch on the throttle
valve with the throttle stop
screw, and fit the throttle
valve into the carburetor.

PY◇ Install a provided main jet.

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

Carburetor gasket◇ Remove a top cap from carburetor,
and pull out a spring andthrottle valve.

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

Throttle stop screw◇ Fit the top cover into the
carburetor, aligning theconvex section on the top
cover with the concave
section on the carburetor.

○ Adjustment of throttle
free play.

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

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

Mesh here asshown below◇ Tighten up the hex nut.
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■ Mounting procedure※ Please refer to the Genuine Service Manual for detailed mounting methods and specified torques that are notspecifically described.

◇ Holding a hex nut, loosen theadjuster.

◇ Install the fuel tank onto theframe with a bolt.
Note: Be sure that you protect
specified torque.
Bolt◇ Tighten two nuts on the rearshock absorber.

◇ Applying the rear brake,
unfasten two bolts.

Note: Be sure that you protect
specified torque.
Nut

Torque：12N・m（1.2kgf・m）

Torque：34N・m（3.5kgf・m）◇ Turning of the adjuster will
adjust the free play.

◇ Remove a plate.

Throttle cable◇ Connect a fuel tube to the
carburetor.

CO
More free play

AdjusterHex nut◇ Pull out a stock sprocket
from the shaft, and remove
the chain.

Less free play

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

◇ Install the side cover.

○ Installation of seat.
◇ Put a hook of the seat stay inbetween two washers of the rearshock absorber to install theseat.

◇ Hold the adjuster and tighten
the hex nut.
◇ By snapping the throttle,checkthat 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 theboot.

○ Installation of air filter.
◇ Attach the band to the air
filter, and fit it into the
carburetor. And fasten the band.

PY◇ Fit a provided sprocket into
the shaft.

○ Installation of drive
sprocket.(on the engine side)◇ Detach a clip from the drive
chain.

◇ Insert a bolt beneath the seat,
and attach a nut.
Note: Be sure that you protect
specified torque.
Nut

Torque：22N・m（2.2kgf・m）◇ Install a provided plate, andtighten two bolts loosely for
now.

Clip

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

○ Installation of fuel tank.
◇ Install the fuel tank onto
the frame.

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

○ About a Driven (rear tire side) sprocket.
※ With change of a drive sprocket, a driven sprocket is also changed and highgear-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.

Note: Be sure that you protect specified torque.
Change pedal

Torque：10N・m（1.0kgf・m）

Hyper-S stage kit A type recommendation sprocket(In the case of 65kg weight)
Tire size

ClutchCentrifugal 3speed
Stock manualStrengthening, special
Stock
Strengthening, special

8inc

Drive
sprocket
16
15
16
16
16

Drivensprocket
30
25
25
25
28

CO

10inc

Ratio
1.87
1.67
1.56
1.56
1.75

◇ Check for slack in the bolts and the like fixed all
the way from the engine to the suspension.
◇ Turn on the fuel cock.

○ About a drive chain.

※ If it changes into a recommendation sprocket from the sprocket of stock, the slackof a drive chain cannot be abolished only by adjustment. It is necessary to use
a chain cutter etc. and to shorten a chain. Moreover, the length of a chain
also changes with the length of 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
Drive
sprocket

Drivensprocket12(Stock)12(Stock)
16
15
16
16

31(Stock)31(Stock)
30
25
25
28

The length of a swing arm, and the number of links of a chain
Stock
4cm
8cm
12cm
16cm
swing arm
StretchStretchStretchStretch72(Stock)－－－－76(Stock)
－
－
－
－
74
78
84
92
100
72
76
84
90
98
72
76
84
90
98
－
－
－
92
100

Master link

◇ If the ignition timing is off, the engine likely
will malfunction seriously let alone fail to exhibit
its original performance. Therefore, it is advisable
to check and adjust the ignition timing without fail.
If you cannot do the work yourself, we recommend thatthe work be done by your local motorcycle dealer.
◇ Using a timing light (Item No. 00-01-009), checkat the time of idling that the“F”mark on the
flywheel aligns with the alignment mark on the
crankcase.

PY◇ Fit the master link from inside to connect
the drive chain, and attach a link plate.

Link plate○ Inspect and adjust the ignition timing.

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

Timing light◇ Adjust the ignition timing by loosening the
breaker-tightening screw and moving the breakerplate a little bit at a time.

Clip◇ Fully tighten the loosely-installed drive
sprocket bolt.

Alignment mark“F”mark

Breaker-tightening
screw

Note: Be sure that you protect
specified torque.
Bolt

Torque：12N・m（1.2kgf・m）

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

Torque：12N・m（1.2kgf・m）

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12/12◇ After the adjustment, rotate the crankshaft so thatthe 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 thepoint.

How to Set the Carburetor
・When the carburetor does not match the engine and the engine fails, the engine failures are caused by either too dense or too lean
air-fuel mixture.
・The engine failure symptoms for the engine are as follows:

When the air-fuel mixture is too dense:

When the air-fuel mixture is too lean:

・The explosion sound with a dull thud continues
intermittently.
・The engine malfunctions further if you use the choke.
・The engine malfunctions when you warm it up.
・The engine works well if the cleaner is detached.
・The motorcycle belches dense (or, black) exhaust gas.
・The plug smolders, getting blackened.

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

CO※ Set the carburetor only after warming up the engine, and then test-drive. And use a plug with the right heat value.
※ Do the setting in the following manner, studying at what throttle opening position the engine starts failing.

○ Jet needle (Throttle position at 1/4 - 3/4)
Whether or not the engine revolution is in proportion to the throttle operation
・When the acceleration is not smooth or even, make the air-fuel mixture dense.
・Make the air-fuel mixture lean when the engine revolution goes up heavily and belches black gas.
The mixture ratio at this throttle position can be adjusted by the location of E-ring in the grooves. The air-fuel mixture
becomes dense as the location of the E-ring moves down from the 1st to the 5th groove.

3rd groove
2nd groove
4th groove

1st groove

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

PY

・The air-fuel mixture ratio at this throttle position can be adjusted by changing the number of the main jet. The larger themain jet numbers, the denser the mixture ratio becomes.
・In view of the engine and muffler specifications, select the most appropriate main jet to get the highest revolutions.

○ Slow jet / Pilot jet (First of all, please adjust the air screw.)・In case you have given more than three turns to the air screw to tighten it, use a slow jet / pilot jet with a small number.
・If you have tighten the air screw (clockwise) to the full, use a slow jet / pilot jet with a larger number.
Check whether you have made a right choice of the pilot jet by seeing if the engine starts up revolving smoothly from theidling to running at slow speed.
・When the engine revolves up unevenly, the slow jet / pilot jet number is too small. (At idle)
・When the motorcycle belches black exhaust gas and produces heavy exhaust sound, the slow jet / pilot jet number is too big. (At idle)
・After replacing the slow jet / pilot jet, you need to readjust the airscrew.

○ Air screw

The air screw adjusts the air mass flow at the time of engine’s revolving at slow speed. (At idling)
・Give the air screw a right turn → The air-fuel mixture gets dense.
・Give the air screw a left turn → The air-fuel mixture gets lean.
Loosen the tightened air screw back to the 1.5-turn position. And then from this position, give to the airscrew a right or left
turn of 1/4 to 1/2 till the engine revolves at the highest speed.
Loosen the idle stop screw till you get the steady idling revolutions. And once again adjust the position of the airscrew to get
the highest revolutions.

● On how the barometric pressure, temperatures and humidity affect the setting:・At highlands or at high altitudes, the barometric pressure and air density go down and the air gets into the carburetor in lessamounts.
This makes the air-fuel mixture dense which was adjusted at low altitudes.
・Under the weather conditions with very low temperatures, the air density increases, which makes the air-fuel mixture lean.
・Under the rainy and humid weather conditions, the air density decreases, which makes the air-fuel mixture dense.

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