80cc Hyper S-Stage Bore Up Kit
Instruction Manual

CO

Item No.

：０１ ‑ ０５ ‑ ００９４

Applicable Model ：Ape (FI)：AC18-1000001〜
Frame No.

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

！ Caution about fuel to use！

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

！Caution about spark plug！

Be sure to replace a spark plug with a supplied CR8HSA (NGK) or U24FSR-U (DENSO). Use a spark plug with the right number, depending on the degreeof burning of the spark-plug electrode section.

Please read the following instructions before installation.

◎The following show the envisioned possibility of injuries to human bodies, and physical loss or damage as a result of disregarding the following cautions.
◎ 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.

PY◎ If you make alterations to the products, we shall be held free from any guarantee of them.
◎ You are kindly requested not to contact us about the combination of our products with other manufacturers’.
◎This kit is designed for exclusive use in the above-mentioned types of motorcycles and frame numbers only. Please take note that this product cannot bemounted on other types of motorcycles.
◎Installation of this kit requires engine removal and mounting. We strongly recommend you to work strictly following HONDA genuine parts service manualfor your vehicle.
◎ For installation, work with reference to the installation procedures with enough care. Besides, this instruction manual, as well as HONDA’s genuine parts
service manual, is prepared for persons who have acquired basic skills and knowledge in tuning. We recommend those who are technicallyinexperienced or without enough tools to ask a technically-reliable specialist shop for the installation work.
◎ We would recommend our TAKEGAWA’s muffler to make your engine more powerful.
◎ Some of bolts, nuts, dowel pins and packing will be reused. However, be sure to replace worn-down or severely-damaged ones with new ones.
◎ Never use liquid packing. It may plug the oil passage, and in the worst case break the engine.
◎ Installation of this product requires left side crankcase cover gaskets (HONDA’s item No. 11394-KN4-750), which please purchase.
The following show the envisioned possibility of injuries to human bodies and property loss as a result of disregarding the following
cautions.
･Work only when the engine and the muffler are cool. (Otherwise, you will burn yourself.)･Prepare right tools for the work, and do the work in the proper and right way.
(Otherwise, improper work could cause breakage of parts or injuries to yourself.)･Always use a torque wrench to screw bolts and nuts tight and securely to the specified torque.
(Improper torque could cause these parts to get damaged or fall off.)･As some products and frames have sharp-pointed or protruding portions, please work with your hands protected.
(Otherwise, you will suffer injuries.)･Before riding, always check every section for slack in parts like screws. If you find slack ones, screw them securely up to the specified torque.
(Or improper torque may cause parts to come off.)･Check carefully gaskets and packings, and in case wear or damage is detected, always replace them with new ones.
CAUTION

The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the
WARNINGS following cautions.
･Please always try to ride a motorcycle at legal speed on the public road, abiding by the law.
･Always drive the engine in a well-ventilated place, and do not switch the engine on in an airtight place.
(Otherwise, you will suffer from carbon monoxide poisoning. )･When you notice something abnormal with your motorcycle while riding down a road, stop riding immediately and park your motorcyle in a safe place.
(Otherwise, the abnormaility could lead to an accident.)･Before doing work, place the motorcycle on level ground to stablize the position of your motorcycle for safety's sake.
(Otherwise, your motorcycle could fall down and injure you while you are working.)･Check or perform maintenance of parts correctly according to the procedures in the instruction manual or a service manual.
(Improper checking or maintence could lead to an accident.)･If you find damaged parts when checking and performing maintenance, do not use these parts any longer, and replace them with new ones.
(The continued use of these damaged parts as they are could lead to an accident.)◎ 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.
‑1‑

Dec./10/ 12

About Screws◇ Usually, counterclockwise rotation loosens the bolts and nuts, and clockwise rotation tightens them.
◇ When tightening a screw, at first tighten it by hand at tight as you can.
◇ To loosen a screw means turning a tightened screw around three or four times counterclockwise, and to unscrew it means turning it aroundcounterclockwise until it comes off.
◇ To tighten a screw means to keep a screw from getting loose. The numeric valve as a guide at which a screw will not break or get loose when tightenedis the so-called “tightening torque”.
◇ If you do not have a torque wrench, please try to tighten a screw as tight as possible to the level where the screw will not break or get loose, though
we can not take any responsibility for the screw 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 at which the screw will break or get loose.
◇ Improper use of tools will result in breakage of the top of a bolt or screw.

CO〜 Kit Contents 〜

２

３
７

１

６

４

Ａ

Ｂ

１２

１０

１１

９

８

５

PY

01-13-021 : Gasket set

７

９
８
２―Ａ

１３

No.
1
2
2-A
2-B
3
4
5
6
7
8
9
10
11
12
13

Parts Name
Piston, 53.5 mm
Cylinder COMP.
Aluminum sealing washer, 10 mm
Oil plug bolt
Piston ring set, 53.5 mm
Piston pin, 13 x 38.5
Piston pin circlip
Cam shaft
Cylinder head gasket
Cylinder gasket
Exhaust pipe gasket
Spark plug
FI Controller (for S-Stage)
Driven sprocket, 35T
Mark set

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

Repair Part Item No.
13104-149-T00
01-01-041
00-07-0010
90145-GEY-T00
13011-GBG-T00
13112-165-T01
00-01-0003
01-08-0123
12251-GEY-T00
00-01-0075
00-01-0027
NGK-CR8HSA
03-05-0014
02-07-3401

in packs of
1
1
10
1
1
1
6
1
1
2
2
1
1
1

※Please order repair parts with the Repair Part Item No. Without the repair part item No., we
may not be able to provide the correct parts.
Some parts are only available as a set. Please order them with the set number.

‑2‑

Dec./10/ 12

〜 Installation Procedures 〜◇After turning off the main switch, disconnect a black
2P coupler from the fuel pump unit.
2P coupler

４．
Cover the just-removed connector with a vinyl in order◇Disconnect a black 5P coupler from the sensor unit.

◇Remove a spark plug.

to prevent the dust and dirt from getting into theconnector.
◇Following the above example, detach the quickconnector on the side of the throttle body.

CO◇Unfastening a mount bolt and a collar, and two pieces
each of bolts and collars, demount the tank.
Fuel tank

Mount bolt
5P coupler

Collar◇Loosen the lock nut to remove the throttle cable fromthe cable holder and throttle drum.

◇After turning on the main switch, crank the engine
more than five times with a kick starter in order todepressurize the inside of the fuel hose.
◇Turn off the main switch.

Wiring Disconnection

HolderCollar●Engine Removal

Fuel pumpunit & cover
Bolt

Sensor Coupler Removal

Cable◇Disconnect a brown 2P coupler from the oiltemperature sensor and a black 2P coupler from

Seat and Tank Removal

the 02 sensor in order to remove 0 2 sensor cordfrom the clamp.

Lock nut◇Unfasten two bolts and collars to demount the seat.

02 Sensor 2P Coupler

Seat

Hook

Drum

Side Cover Removal◇Loosen the connecting tube band screw and insulator
band screw to remove the throttle body.

◇Unscrew a bolt on the right side cover.

PY
Band screws

The cover can be removed by detaching two bosses
from the frame.

Right side cover

Bolts & Collars

fully-closed position.

Bossesbody to malfunction.

Exhaust Muffler Removal◇Take off two nuts on the cylinder head side.

an air-blower, and cover the portion with a waste
cloth.
On the side of thethrottle body

5P Coupler

Wire band◇Disconnect the wiring of the breather hose.

Left side cover(+) Cable

２．
Clean the portion around the quick connector with

2P Coupler※Never hit the throttle body hard like dropping it.
Otherwise, the severe shock may cause the throttle

the frame, then the side cover becomes detached.

(-) Cable

Rubber band

coupler from the side stand switch and a brown 5P
coupler from the AC generator.

Throttle body

◇Dismount three bosses on the left side cover from１．
Disconnect the cable from the battery.
Battery

2P coupler from the oil temperature sensor◇Unfasten a wire band, and disconnect a green 2P※After removing the throttle cable from the throttle body,never snap the throttle valve from the full-bore to the

Bolt※ How to remove the quickconnector:

BossesSensor cord &clamp◇Unfasten the screw to remove the throttle drum cover.
Screws◇Unscrew and remove mounting bolts and washers,
and detach an exhaust muffler.

On the side of the fuelpump unit◇Loosen the nut on a clutch cable guide, anddisconnect a clutch cable from a lifter lever.

Cover◇Disconnect a black 4P coupler from IAC valve and a

Quick connector

black 2P coupler from the injector.
３．
Press in the retainer tab to detach the lock tabfrom the connector. And pull out the connector.
Lock tabRetainer tab

4P coupler

2P coupler

Spark Plug Removal◇Pull a plug cap to demount it. Be sure to pull the cap,
not a wire.

Connector

Joint rubber‑3‑

Dec./10/ 12

◇Disconnect the clutch cable from the cable guide.

◇First, pull out the upper side bolt and then remove a

Left Step Removal◇Unfasten a lock bolt and a set plate, and remove an

collar and the clutch cable guide.

◇Remove the side stand switch cord from the frame.

adjuster.

Set plate

CO

Lock bolt◇Unscrew two bolts, and remove the left step.

Drive Sprocket Removal◇Unscrew five bolts on the left side crankcase cover,and remove the left side crankcase cover.

◇Take out the bolt on the lowr side, and detach theengine from the left side of the frame. Be careful not to◇Remove two hex’ bolts from the cam sprocket.

give scratches to the frame.

Engine Removal◇Place a jack or substitute stand under the engine tohold up the engine.

◇If the gasket material remains on the mating
surfaces, get rid of it with a cutter or a scraper.
◇Remove a spacer in advance.

PY◇Detach the cam sprocket from the cam shaft andthen, from the cam chain.

◇Detach four nuts on a front engine hanger, take fourbolts out, and remove the front engine hanger.

●Removal of Cylinder Head,Cylinder, and Piston
Cylinder Head Removal◇Unscrew two bolts on the cylinder head cover, andSpacerremove the cylinder head cover and its gasket.

◇Unscrew two bolts on the drive sprocket, and◇Loosen an adjust bolt and lock nut at the back of thecylinder.

remove a fixing plate and the drive sprocket.

Lock nut◇Remove a nut on the upper rear engine mount.

Adjust bolt

◇Demount a cylinder head mounting bolt.

◇Remove a bottom side nut also.

◇Fix a flywheel, and loosen two hex’ bolts on a cam
sprocket.

‑4‑

Dec./10/ 12

◇After loosening 4 camshaft holder nuts diagonally◇With a cutter or a scraper, get rid of the gasket scraps

in a few steps, detach 4 washers, a camshaft holder,remaining on the cylinder head plane on which to fit aa camshaft, a bush and a dowel pin.

manifold.

◇Detach a spring, and remove a cam chain tensioner
from the cylinder.

Mating Surface Cleaning◇Completely get rid of the gasket scraps on themating surface with a cutter or a scraper.
Be careful not to give scratches to the surface.

CO◇Wipe the surface with a waste cloth.

Cylinder Removal◇Remove the cam chain guide, and pull out thecylinder. (If it is hard to pull it out, hit the cylinder lightly
with a plastic hammer.)◇Plug the cylinder hole on the crankcase and a cam
chain hole with a waste cloth or clean rag not to let any
dirt or part fall into the hose.

Cam chain guide

PY● Crankcase Modification※In fixing the cylinder onto the crankcase, in somecases a cylinder sleeve and a crankcase sleeve

Piston Removal◇Suspend the cam chain with a wire or the like tokeep it from falling into the case.

◇Remove one of the two piston pin circlips.

◇Take off two dowel pins in advance and keep them for
re-use.

hole may interfere with each other, due to right andleft crankcases being out of alignment and for otherreasons. Since the use of these parts as they arewill lead to sleeve deformation and engine troubles,
do not fail to check these parts for the interference.

※You can remove it by prising it open with a screwdriverwith its tip on the notch.

Cylinder sleeve

Interference part

◇Plug the hole in the crankcase with a waste cloth◇Remove the cylinder head.

not to let cutting chips get into the case.
◇Scrape the convex parts on both right and left

◇Remove a lock nut and an adjust bolt from the cylinder.

◇Push out the piston pin with a driver or the like in the
direction where one of the two circlips has just been

crankcases till the mating surfaces become level.

◇After scraping, remove the cloth with enough care
not to let any chip get into the case.

removed.

Left side
crankcase

Right side
crankcase◇Detach two dowel pins in advance and keep themfor re-use.
After scraping◇Now you can take out the piston.
◇Stuff up the sleeve hole with some clean cloths.
◇After installation of the kit, idle away the engine fora few minutes, and replace the engine oil with thenew one without delay.

‑5‑

Dec./10/ 12

●S-Stage Kit Installation◇Fix the second ring, turning up the side with an◇Attach two dowel pins and a cylinder gasket to the

Cylinder Installationengraved letter “N”.

crankcase.

◇Insert the cam chain tensionner into kit’s cylinder, andPiston Installation

hang the hook of the spring on the cylinder.

◇Fix one of kit’s piston pin circlips to a pin hole.
※Place a circlip so its end gap does not meet with
the notch on the pin hole.
※You can rather easily install it by pressing it intoCOthe piston with a screwdriver, but taking care not todamage the piston with a screwdriver.
※Do the job carefully as, in some cases, the circlip
comes off flying while you press it inside.

◇Fix the top ring, turning up the side with an engraved

Gasketletter “N”.

◇Apply engine oil to the inside of the cylinder andspread it with fingers to be equally applied all over.

◇Place the cam chain tensioner in a position so the end◇Fix piston rings according to the figure below.

of the rod will be nearly on the same level as the clamp
face.

◇Apply engine oil to the piston pin hole.

Top
ring
ト
ップリング
120°

120°

120°

Secondセカンドリring
ング
エキスパンダー
Expanderサイド
Side レール
rails

Dowel pins

Fix it with an adjust bolt and tighten the lock nut.
◇Apply engine oil to whole surface of the piston, andthe piston rings.

PY
Rod’s end

◇Apply engine oil to a piston pin hole in the con’rod.

60°

60°

◇Fix the oil ring expander.

◇Let the cylinder in.

◇Apply engine oil to the piston pin and place the piston

in a position so the “EX” mark on the upper side of thepiston faces the front or exhaust side.

◇Remove the waste cloth.

◇Insert the piston into the cylinder gradually by hand◇Fix the lower oil ring side rail.

with care not to shift the piston ring’s end gaps outof the position.

◇Degrease the mating surfaces of the crankcase
and the cylinder with thinner or the like.

◇Fix the upper oil ring side rail.
◇Fix the other piston pin circlip, included in the kit, to thepin hole.
※Place the circlip in a position so the end-gaps of apiston pin circlip do not meet with the notch on the hole.

◇When the piston is completely in the cylinder, pass
the cam chain through the cylinder and install thecylinder to the crankcase.

※It is relatively easier to press it by a driver with care not
to give scratches to the piston.
※Do the job carefully as, in some cases, thepiston pin
circlip may come off flying while you press it inside.

‑6‑

Dec./10/ 12

◇Insert the cylinder, fitting the end of a cam chain
guide into grooves in the crankcase and the◇Install an adjuster, passing it through the cam chain◇Attach four washers, and tighten four nuts evenly anddiagonally in a few steps.

tensioner and the cylinder head.

protrusion into grooves in the cylinder.

◇Align cam shaft’s bolt-holes with the cam sprocket.
Then attach two hex’ bolts to the holes by hand
temporarily.

Caution: Apply the specified torque.
Torque: 20 N・m (2.0 kgf・m)ProtrusionCOTop end◇Temporarily attach a set plate with a lock bolt.
“O” mark

カムチェ
Cam ーンガイド
chain

シリンダー

guide

Cylinder◇Fully tighten the cylinder head mounting bolts.
Be careful not to get the cam chain jammed between

Crankcase
クランクケース

the cylinder head mount and camshaft.
Caution: Apply the specified torque.
Torque: 12 N・m (1.2 kgf・m)◇Temporarily tighten the cylinder head mountiong◇Fix the flywheel and fully tighten the hex’ bolts on
the cam sprocket.

bolts.

Cylinder Head Installation◇Degrease the mating surfaces of the cylinder andthe cylinder head with thinner or the like.

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

PY◇Check that “T” mark on the flywheel is aligned with the“▽” mark on the crankcase.

Installation of Cam Shaft and
Cam Sprocket◇Apply engine oil to the journal and cam surfaces of the

Cam Chain Adjustment

cam shaft, and install the camshaft to the cylinder headwith the camshaft’s cam top facing downwards.
Bush

Cam shaft

Join together※A cam chain, whether tightly or loosely streteched,will impair the engine conditions. Perform thisprocedure correctly.
◇Rotate the flywheel till both cam tops of the cam
shaft point up.

◇Install the cam chain in the position so the “O” mark on
the cam sprocket is right at the top. Fit the cam sprocket

Cam tops should point this way.

into the cam shaft.

◇Attach two dowel pins and a cylinder head gasket
to the cylinder.
Dowel pins

◇Attach two dowel pins, and as shown in the photo,route the camshaft under the chains.

◇Rotate the flywheel a little, and then rotate the cam
sprocket to mark it easy to install hex’ bolts.

◇Rotate the flywheel a little by hand. Depending on
how tensely or loosely the cam chain is stretched tothe camsprocket, turn the flywheel in either
direction to get the proper tension of the cam chain,
watching the “O” mark on the adjuster.

Cylinder head gasket◇Pass the cam chain through the cylinder head andinstall the cylinder head to the cylinder.
◇Install the cam shaft holder.

Adjuster
ゆるむ
Loosen
標準位置Standard position
張る
Tighten
セッ
トプレート
Set
plate

Lock bolt‑7‑

Dec./10/ 12

◇Tighten the lock bolt fully when the cam chain is◇After tightening the nut, double check the valve

found stretched properly and you can move theclearance with the 0.1mm thickness gauge.

flywheel without difficulty, and fix the adjuster.

◇Pour fresh engine oil to a oil pool on the cylinder
head to the brim.

Caution: Apply the specified torque.

◇Temporarily tighten the two nuts.

Installation of Left Side
Crankcase◇Degrease the clamp faces of the left side
crankcase cover and the crankcase with thinner or

Torque: 10N・m (1.0 kgf・m)

the like.
◇Attach a spacer, and install the left crankcase coverand a new gasket to the crankcase by tighteningCOfive bolts.
Caution: Apply the specified torque.
Torque: 12 N・m (1.2 kgf・m)◇In case you can not get the proper tension of the◇Install the cylinder head cover and its gasket to thecam chain only by adjusting the adjuster, thenadjust the tension with the adjust bolt on thecylinder head by tightening two cylinder head coverbolts.

cylinder.
◇Fix the adjuster where it has the best tension. Then

Caution: Apply the specified torque.
Torque: 12 N・m (1.2 kgf・m)loosen a lock nut on the cylinder, and loosen theadjust bolt a little bit.

●Engine Mounting
Engine Mounting◇Attach a front engine hanger, and insert four bolts

PY◇Fix the drive sprocket with the drive chain to thecounter shaft.
If it is hard to fix the drive sprocket, fix it while shaking◇Place a jack or a proper stand under the engine tosupport the engine. Then mount the engine from thethe engine lightly.

left side of the vehicle.
◇Insert a bolt into the lower part of the rear engine◇Fix the adjust bolt with a flat tip screwdriver, andtighten the lock nut.
Caution: Apply the specified torque.
Torque: 12 N・m (1.2 kgf・m)◇Again, move the adjuster and hold it where thecamchain has no slackness and you do not feel it
hard to rotate the flywheel. Then tighten the lockbolt to fix the adjuster.

mount from the left side.

◇Stretching the drive chain moderately loosely, fully

Valve Clearance Adjustment◇Rotate the flywheel counterclockwise, and stop
rotating it where the “O” mark on the cam sprocket
is on the top and the “T” mark on the flywheel isaligned with the “▽” mark on the crankcase.
◇Insert a 0.1mm thickness gauge between theadjust screw and the end face of the valve(or, valve clearance).

Spacerfrom the left side and temporarily tighten four nuts.

tighten the two nuts on the rear engine mount and theInstallation of Left Side Step
◇Install the left side step to the frame with two bolts.
Caution: Apply the specified torque.
Torque: 26 N・m (2.7 kgf・m)◇Fix the side stand switch cord on the clamp of theframe.

four nuts on the front engine hanger plate.
Torque:◇Join a collar and a clutch cable guide together, andinsert a bolt into the upper part of the rear engine
mount from the left side.

Caution: Apply the specified torque.

rear engine mount nut: 44 N・m (4.5 kgf・m)

front engine hangar plate nut: 26 N・m (2.7 kgf・m)◇Fit the fixing plate into the counter shaft to align withthe threaded holes on the drive sprocket, and fix two
bolts.
Caution: Apply the specified torque.
Torque: 10 N・m (1.0 kgf・m)

Wiring◇Connect a green 2P coupler from side stand switch
and a brown 5P coupler from AC generator, andfasten them onto the frame with a wire band.
2P coupler◇Adjust the position of the adjust screw so that
there is a little resistance to pulling the gauge out.
Then tighten the nut.
Caution: Apply the specified torque.
Torque: 10N・m (1.0 kgf・m)

5P coupler‑8‑

Wire band

Dec./10/ 12

◇Connect the breather hose.

◇Temporarily tighten two mounting bolts and washers.

◇Connect a black 5P coupler from the sensor unit.

Installation of Seat and Tank
◇Fix the fuel tank onto the frame, and screw up thebolt.
Caution: Apply the specified torque.
Torque: 26 N・m (2.7 kgf・m)◇Install the fuel pump unit.

CO

Caution: Apply the specified torque.
Torque: 12 N・m (1.2 kgf・m)
5P coupler◇Attach the clutch cable to the lifter lever and install
it to the clutch cable guide. Then tighten the nut.

Fuel tank

Mount bolt

◇Connect a black 4P coupler from IAC valve and a◇Here, tighten firmly three loosely-tightened parts.

Collarblack 2P coupler from the injector.
4P coupler

Caution: Apply the specified torque.

2P coupler

two nut : 12 N・m (1.2 kgf・m)mounting bolt : 13 N・m (1.3 kgf・m)

CollarFuel pump unit
& cover
Bolt◇Firmly tighten the loosely-tightened three parts.
Caution: Apply the specified torque.
two nut : 12 N・m (1.2 kgf・m)

Lock nut : 34 N・m (3.5 kgf・m)◇Fit the hook in the front on the back side of the seat

◇Insert the kick pedal into the shaft, and tighten it witha bolt.

into the frame, which please fix to the frame with twobolts and a collar.
◇Install a throttle drum cover and tighten the screw to

Caution: Apply the specified torque.

Caution: Apply the specified torque.

the specified torque.

Torque: 12 N・m (1.2 kgf・m)

Torque: 26 N・m (2.7 kgf・m)

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

PY

Throttle body Installation

Seat

Hook

Screws◇Aligning the protrusion with the grooves, install thethrottle body onto the insulator. Tighten up the bandscrew until the distance between the edges of theinsulator band comes down to 7 mm ± 1 mm, or 8 mm
to 6 mm.

7 mm ± 1 mm, or 8 mm to 6

Spark Plug Installation◇Screw kit’s spark plug by hand at first.

Cover◇Then tighten it with a plug wrench.

◇Fix the throttle valve to the carburetor by aligning a

Caution: Apply the specified torque.
Torque: 14 N・m (1.4 kgf・m)

notch on the throttle valve with the throttle stop screw,
and install the top cap to carburetor.

●Installation of an FI controller.

◇Please install the FI controller referring to its
instruction manual.

◇Install the connecting tube onto the throttle body, andtighten up the band screw firmly.
Band screws◇Fix a plug cap.

Bolts &Collars※How to connect the quick connector.
Once you have disconnected the quickconnector, it is advisable to change the retainer
and joint rubber with new ones.

１．
After joining two protrusions on the lock tab andholes in the connector together, install theretainer to the connector.
Connector● Side Cover Installation

Retainer◇Fix the left side cover by fitting three bosses on thiscover into the frame.
BossesJoin together

Join together
Throttle bodyPin

２．
Install the joint rubber onto the joint.

※Please check that the hole in the band is right on theinsulator-locating pin.

３．
Install the quick connector straight onto the joint,◇Connect the throttle cable to the throttle drum, and fix

with the joint rubber. Press in the connector until
it clicks. If you cannot easily install the connector,

and, as shown in the picture below, align thegrooves (or the recessed portions) of the retainer

the cable to the cable holder.

Exhaust Muffler Installation◇Temporarily tighten two nuts on the cylinder headside.

◇Loosely tighten the lock nut for now, and adjust the freeplay at the throttle grip.

Left side cover◇Fit two bosses on the right side cover into the frame,
and fix the bolt.

HolderRight side
cover

Cable

apply a thin coat of engine oil to the joint.
Joint rubber
Connector

BossesJoin together
Lock nut

Drum※Insert the stock muffler from between the step andengine.
Bolt‑9‑Dec./10/ 12

４．
Move the connector back and forth, and checkthat the connector is firmly held by a lock tab andconnected securely.

◇Take out the axle shaft, remove a rear caliper by●Driven Sprocket Installation
and Chain Adjustment

sliding it backward, and then remove a wheel.

Wheel Installation◇Attach collars to the right and left sides of the wheel.

※Always stop the engine when working.

Lock tab

Drive Chain Removal◇Remove a clip.

CO
Connector

Clip

５．
Connect a black 2P coupler from the fuel pumpunit.

2P coupler◇Remove a link plate and a master link, and then a drive
chain.

Master link

◇Detach collars on the left and right sides of the wheel.
◇After setting the wheel, install the rear caliper.

６．
Connect the battery cable.
７．
Keep the main switch turned on for a few sec
onds to check for fuel leakage. (At this point,
never start the engine.)connector on the side of the throttle body.

◇Please separately purchase an FI Controller

available as an optional extra, which please installfollowing the instructions in its Instruction Manual.

PY

Link plate◇Referring to the above, connect the quick

Wheel Removal◇Loosen an adjusting nut.

◇At this point, check the following three points: (1)Adjusting nut☆ Engine Starting ☆
○Wipe off the dirt and dust on the engine.
○Turn ON the ignition key, and start the engine.
Work only in a well-ventilated place.
○Check for any abnormality such as an abnormalsound.
○If nothing abnormal is detected, carry out ashakedown for about 30 to 50 km, and check thevalve clearance again.
Work only when the engine and the muffler
are cool.
○Carry out a shakedown again for about 100 to 150
km.
○After the shakedown, double-check for any
abnormality such as an abnormal sound andblow-by gas.
(If any abnormality is detected, disassemble theengine again and check each section.)
Never re-use parts which cannot be re-used.

◇Holding an axle shaft, remove an axle nut and washer.

the convex part of the rear caliper fits into the rail ofan swing arm; (2) collars fit into the right and left
sides of the wheel; and (3) a rear caliper brake padpresses firmly the rear disc.

Rail

Stock Driven-Sprocket Removal◇Remove three nuts first, and then a stock driven
sprocket.

Convex part
Left side collar

Driven Sprocket Installation◇Install a kit’s driven sprocket and then three nuts onto
the wheel.

Pad presses firmly the disc.

Caution: Apply the specified torque.
Torque: 54 N・m (5.5 kgf・m)

Right side collar◇Check that the washer is through the axle shaft.

‑10‑

Dec./10/ 12◇Adjusting the positions of the wheel, the rearcaliper, and the swing arm, insert the axle shaft.

Adjustment of Drive Chain Free ● Left-Side Crankcase
Installation
Play◇Rotate the right and left adjusting nuts to adjust thefree play on the drive chain, but see to it that the scales

Axle nut

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

Adjusting nut

Scale reading

Lock nut◇Check the free play at around the mid-point of the
sprocket in the riding condition.
Free play: 25-30 mm

Spacer※When the stock sprocket is changed to the kit’s

driven sprocket, it’s impossible to cancel theslackness of the drive chain just by adjusting the

２５〜３０ｍｍfree play. You need to shorten the chain by cutting
it with a chain cutter or the like.

◇Holding the adjusting nut, tighten the lock nut.

◇In case of a stock chain, cut four links off the chain.

ドライブチェ
Drive
chain ーン

２

４
こでカットします
Cutこhere◇Fix the drive chain to the drive sprocket and thedriven sprocket.
◇Fit the master link from inside to connect the drive
chain, and attach a link plate.

Master link

Link plate

Caution: Apply the specified torque.
Torque: 62 N・m (6.3 kgf・m)※ The installation of this Kit will
increase the power of yourengine. So with the stock
sprocket, every hardware will getworn 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, please make the

PY◇Holding the axle shaft, tighten the axle nut.

Drive Chain Installation② Change of sprocket

sprockets to be with a high gear
ratio.
◇ Ape : The referential secondary
reduction gear ratio of S-Stage is
2.5 (when the driver weighs 65
kgs).
The secondary reduction gear
ratio is figured out by the

Cutting Drive Chain

１

Always replace the gasoline withhigh-octane gasoline whenregular gasoline is remaining in thefuel tank.

and a new gasket to the crankcase with five bolts.

◇Loosely tighten the washer and the axle nut.

３

① About fuelcrankcase cover and the crankcase with thinner or the
like.
◇Attach the spacer, and fix the left-side crankcase coveron the right and left are the same.

CO◇Degrease the mating surfaces of the left-side●Cautions Before Runningfollowing calculation: The numberof teeth of the driven sprocket on
the rear side ÷ the number ofteeth of the drive sprocket on theengine side.
Example: 35T (driven sprocket) ÷
14T (stock drive sprocket ＝ 2.5(secondary reduction gear ratio)● Other notes① Oil Cooler◇ The installation of this Kit
increases the heat release valueof the engine, set off by theincrease in power. Therefore, we
recommend that you equip yourmotorcycle with an oil cooler Kit(09-07-2154: 4 fins, 5 oil lines,
09-07-2153: 3 fins, 4 oil lines) for◇Attach a clip.

long-hour high-load driving.

② Thermometer※Arrange the position of the ring-end gap to be in◇ A stick-type temperature sensor
is installable on the cylinder side

the opposition direction of the vehicle’s movement.

Clipof this kit.

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‑11‑

Dec./10/ 12