Hyper S-Stage V KIT B Type Instruction Manual
Now a new kit is available from us which can bore up to 88cc with a stock 55cc cylinder head installed.
Thus, with this kit you can enjoy the feeling of a heavy engine. We have developed this kit as a street youth
kit which you can assemble as easily as a plastic model and with which you can study the engine structure.

０１−０５−００８４
Item No.
Monkey, Gorilla Z50J-1600008 〜 1805927

・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

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

Notice about sprocket

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

PY

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.
◎ A stock carburetor will interfere with the supplied cylinder. So, please process the interefering part in case you install a stock carburetor.
◎ If you use a stock carburetor, do not remove the air cleaner box or an air cleaner elements. If you change the carburetor, please do the setting to match
various conditions like weather and temperatures. Disregarding these instructions will result in engine troubles and serious accidents.
◎ You cannot run the motorcycle in the rain with kit’s filter installed. Otherwise, it could cause the engine trouble.
The following show the envisioned possibility of injuries 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.)‑1‑2022.12.2

◎ 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 aroundcounterclockwise until it comes off.
◇ To tighten a screw means to screw it up to keep it from getting loose. The numeric value as a guide at which a screw will not break or get loose whentightened is the so-called "torque." If you do not have a torque wrench, please try to tighten a screw as tight as possible to the point where the screw
will not break or get loose, though we can not take any responsibility for the breakage. In case you do not use a torque wrench, you need to judge, only
by intuition or using experience, the degree of tightening power at which the bolt will break or get loose.
◇ Improper use of tools will result in breakage of the top of a bolt or screw.

CO◇ Kit includes:

０１―０２―５１７
Piston kit

１

５

３

２

４

９

１１

１３

PY
７

６

８

１５

１６

１７

１２

１４

１０

１９

２０

２２

２１

１８

No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14

２３

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

Repair Part Item No.
13101-NSH-T00
01-15-014
13111-GEF-T00
00-01-0003
01-01-0222
00-01-0067
12251-GFL-T10
00-01-0156
00-01-0157
00-01-0158
00-01-0034
00-01-0064
00-01-0066
01-08-034

２７

２４

２５

Part Name
PistonPisston ring set
Piston pin 13 x 36
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 (Black)
Camshaft

２８

in packs of
1
1
1
6
1
2
1
2
2
2
4
2
2
1

No.
15
16
17
18
19
20
21
22
23
24
25
26
27
28

２６

Part Name
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
2
2
2
1
1
1
1
1
1
1

Repair Part Item No.
03-03-0060
17111-GEF-T10
03-01-106
00-00-0121
00-01-0159
00-00-0089
00-00-0090
09-02-0071
02-05-041
00-03-0185
00-03-0010
03-03-001

in packs of
1
1
1
10
2
10
10
1
１
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.
‑2‑2022.12.2

‑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

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)

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

CylinderThese hardware is not included in the kit orwill not be used for the installation of this kit.
Be sure to change to CR8HSA (NGK) or
U23FSR-C (DENSO).

※3

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

CO

2022.12.2

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

◇Turn off a fuel cock.

Extension (medium )◇Remove a side cover.

◇Remove the nut, fastened on the rear side of the◇Remove the fuel cock and install the one in the kit.
Tool to use

Tool to use
Socket, 10 mm

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

muffler, by turning it counterclockwise.
Tool to use◇Unfasten a bolt on the air-cleaner stay.

Socket, 10 mm
Extension (medium)

Extension (short)

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

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

Socket, 10mm
Extension (short)counterclockwise.
Tool to use◇Pull the seat backward to demount it.

Open-end wrench, 10 mm‑4‑2022.12.2

6. Remove a spark plug.

9. Remove two tappet caps.

11. Unfasten cylinder-head side bolt.

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, turn
◇Remove two tappet caps by turning them
the plug counterclockwise to remove it.
counterclockwise.

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

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

Tool to use
Offset box wrench, 17 mm

clockwise.
Tool to use◇Remove the cylinder head from the cylinder bypulling the head away from the cylinder. (If it does
not come off easily, strike the cylinder head lightly

Open-end wrench, 10 mmwith a plastic hammer, and it will come off. )Guide roller bolt

10. Remove a cam sprocket.

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.
Then the bolt will come off.
Tool to use

Side bolt◇Turn counterclockwise the guide roller bolt on the◇Pressing the front tire, remove the cylinder head.
cylinder and the side bolt between the cylinder and the
Now you can see the reason why you have let the air
crankcase to loosen these bolts.
out of the tire.
Tool to use◇Be sure to save two dowel pins for use later.
Open-end wrench, 10 mm
Offset box wrench, 10 mm

PY“O” mark stamped here
Notch

Socket, 10 mm

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 topull it out, hit the cylinder lightly with a plastic
hammer.)◇Holding the flywheel, remove three hex bolts on the
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
Offset box wrench, 10 mm

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

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

Cross tip screwdriver, (large)

forward, holding the tire with a hand.

‑5‑2022.12.2

15. Remove the piston.

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

Installation of S-Stage Kit

exercising great caution not to scratch the crankcase.
In case the crankcase center gaskets squeeze out into

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

◇ Cut off the gasket squeezing out at the section pointed
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 thepiston 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
attached.

◇Remove the piston.

16.Remove cylinder gasket, o-ringand dowel pin.
Cylinder gasket

Precautions for installation ofcylinder:◇Fix oil ring expanders.

Exhaust markLeft

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 may◇You can rather easily install it by pressing it into theinterfere with one another. Since suchpiston with a screwdriver, but taking care not tointerference will lead to sleeve defordamage the piston with the screwdriver.
mation and cause engine troubles, do◇Fix the piston pin circlip first on the left side.
not fail to check the existence of interTool to use
ference and eliminate the interference,Flat-and fine-tip screwdriver
if any.
The difficulty level of the work is quite ◇Apply engine oil to the piston-ring grooves, and fix
high. So, you may feel like having come piston rings in the order of an oil ring expander, lower
close to the professional level if you oil ring side rail, upper oil ring side rail, second ring,
have successfully completed the work. and top ring.

side

PY

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
Top
ring
トップリ
ング
the lower one.
120°
3.After rasping the mating surface,remove the waste cloth with care
not to let the shavings get into the
120°
120°
crankcase.
4.After removing the waste cloth, stuff セカンドリング
Second ringup the crankcase opening with a
Expander
エキスパンダーclean 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 new
one without delay. And there is60°
60°
nothing more to do.
Right-side
crankcase◇Fix a lower oil-ring side rail.

◇Fix an upper oil-ring side rail.

◇Fix a second ring.

Left-side
crankcasegasketOn the top-ring front surface
is stamped “R”, and “RN” on
the second-ring front surface.
◇Fix a top ring.

O-ringAfter correction

Top ring
Second ring

SleeveInterferenceSide rail

ピスト
ン
PistonCylinderExpanderPay attention to thecross section as well.

‑6‑2022.12.2

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.

◇Install the cylinder gaskets and rubber packing.

Exhaust mark◇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 the 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 guideroller and guide-roller bolt hole on the cylinder justcylinder and spread the oil evenly with fingers.

mesh together.

◇Tighten the tappet screw on the rocker arm byturning it clockwise.

◇You can rather easily install it by pressing it into thepiston with a screwdriver, but taking care not todamage the piston with the screwdriver.
Do the work carefully as, in some cases, the circlip◇Pressing the tire, install the cylinder.

comes off flying while you are pressing it inside.
So, wear protective eyeglasses for your eyes lest it◇Install the guide roller bolt.
(Tighten it only finger tight at this point.)

should get into your eyes.

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

◇Remove the stuffed waste cloth.

◇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.)◇Fix two dowel pins into the cylinder.

your best.

‑7‑

Dec./13/ 12

CO◇Attach a head gasket.

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 camshaft washer.
◇Holding the flywheel, tighten up three cam sprocket◇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,

bolts.
Tool to use

when the engine viewed from the front.)

Socket, 8 mm
Caution: Apply the specified torque.
10 N･m (1.0 kgf･m)

Offset box wrench, 14 mm

PY
for a guide roller bolt
10 N･m (1.0 kgf･m)

Caution: Apply the specified torque.
Torque: 9 N・m (0.9 kgf・m)

for lower and upper side bolts

6.Adjust the cam chain.

5. Installation of cam sprocket.

Notch

６角ナット
Hex nut◇Hold the cam chain by sticking the screwdriverthrough the cam chain into a middle hole on thecamshaft so the cam chain will not fall into thecylinder.

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

Adjust bolt B

hole

Adjust bolt A◇Loosen the 8mm nut and the adjust bolt A, then the
cam chain will be adjusted automatically by the spring.

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

But in case the cam chain is not stretched tight, keep
the loosened adjust bolt A as it is, and gradually tighten

wrench is not available, tighten them diagonally,
securely and little by little.)
Tool to use
Socket, 10 mm
Caution: Apply the specified torque.
Torque: 12 N・m (1.2 kgf・m)

the adjust 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.

Notch

7.Adjust valve timing and tappet.

◇Turn the cam shaft's hole toward the notch on the
The difficulty level of the work is quite high. Please try
cylinder head. This arrangement sets the cam shaft atyour best.
TDC (Top Dead Center) position.
※In installing the optional cam, please refer to its
instruction manual.

Beware of thispositioning mark

Notch

◇The arrow should face downward.

◇Attach a head-side bolt. Tighten fully the guide roller“O” mark stamped herebolts and the cylinder side bolts which were tightened
temporarily.
Tool to use
Open-end wrench, 10 mm
Offset box wrench, 10 mm※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 thenotch on the cylinder head mesh together. Then, attach
the cam sprocket to the camshaft.

‑8‑

Dec./13/ 12

NotchCO
Flywheel side

◇Turn the flywheel until the “O” mark on the camshaft
and the “T”mark on the flywheel mesh with each

◇ Install two flange collars squeezing the exhaust pipe.
(Set the anti-rotation stopper)◇After adjusting the tappet, turn the flywheel
counterclockwise twice by hand, and then, align “T”
and “O” marks each other.

notch. 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
sprocket.

◇Tighten two nuts on the exhaust pipe, loosely forthe moment.
Tool to use
Open-end wrench, 10 mm

Valve clearance
on the intake side

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

Valve clearance
on the exhaust side
Adjust screw

PY◇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

◇ 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)

9. Installation of spark plug.

◇Install two tappet caps.
Tool to use
Offset box wrench, 17 mm◇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
stem end, can be pulled out with only a little
resistance. If you have no idea of the proper
resistance in pulling out 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 the space but the 0.03mm gauge goes inquite loosely, this means that roughly 0.05mm
clearance is secured. Set the space at 0.05 mm bothfor intake and exhaust.
Tool to use
Needle nose plier

Caution: Apply the specified torque.
Torque: 12 N・m (1.2 kgf・m)◇ Install loosely for now a hex bolt to hold the muffler.
Tool to use◇Install a provided plug with in-vehicle tools or spark
plug wrench.
Tool to use

Spark plug wrench

8. Installation of cylinder-head left-side
cover.

Caution: Apply the specified torque.
Torque: 11 N・m (1.1 kgf・m)◇Attach a plug cap to the plug.

Socket, 12mm
Extension (medium)
Caution: Apply the specified torque.
Torque: 26 N・m (2.7 kgf・m)◇Tighten up three portions which have just been loosely
tightened for the moment.

11. Installation of front fender.

10. Installation of stock muffler.

Offset box wrench, 9 mm
Thickness gauge◇Fasten two hex bolts on the reverse side of the front
fender.
Tool to use◇Attach a cylinder-head left-side cover gasket andleft-side cover.
(Set the anti-rotation stopper of the left-side cover toprevent the cover from turning to the right when the

Socket, 10 mm
Extension (short)◇In installing the muffler, route the tail pipe inside therear shock absorber first, and then set the flange to bebolt is being tightened.)roughly under the exhaust port.

Caution: Apply the specified torque.
Torque: 10 N・m (1.0 kgf・m)◇Pump a tire.

‑9‑

Dec./13/ 12

12. Installation of throttle cables.

Throttle cable◇Disconnect wiring on the stock throttle cable.
More free
play
遊びが多く
なる

アジャスタ
ー
AdjusterCO

六角ナッ
Hex nut ト◇Fix the upper throttle housing with two screws.

Less free play
◇Remove a top cap of carburetor, spring and throttle※Tighten up the screw in the front first, and then the one
valve.
in the back.
◇Attach a top cap, spring and throttle valve to the throttle ◇Turning of the adjuster will adjust the free play.

◇Loosen the hex nut.
Tool to use

cable.

Join together
here.

About 5 mm

Notch

Open-end wrench, 14 mm

Throttle stopscrew
◇Adjust the free play at the throttle grip to be about
5 mm◇Hold the adjuster and tighten the hex nut.
Tool to use※In the case of a stock steering handle, align the joint on
the throttle housing with an “O” mark on the steering

Open-end wrench, 8 mm

handle.
◇Connect the throttle cable wiring.

◇Unfasten two screws to remove an upper throttle
housing.

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

◇Tighten up a hex nut.
Tool to use

Open-end wrench, 14 mm

13. Change of main jet.
Main jetscrew, and attach in a carburetor.

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 even

Socketcap
screws 6x30

PY

when you turn the steering handle all the way to theright and left.
◇Cover the adjuster with the boot.

GasketInsulator

16.Installation of air filter.

GasketFloat pin

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

◇Attach a gasket, an insulator, a gasket and an inlet pipewith socketcap screws 6x30 in this order.

◇Unfasten four screws to remove the float chamber.
Tool to use
Cross tip screwdriver, (medium)

Tool to use
Hex wrench, 5 mm

※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
Flat tip screwdriver, (medium)

Caution: Apply the specified torque.
Torque: 10 N・m (1.0 kgf・m)◇Attach the band to the air filter, and fit it into the
carburetor. And fasten the band.

◇Install the float chamber, and attach it to the carburetor
with four screws.

15. Adjustment of throttle free play.

17.Installation of fuel tank.

※To avoid interference with the crankcase, please cut
the drain section by nippers.
◇Remove a stock throttle cable from the lower throttle
housing.

14. Installation of carburetor.
Lock nut◇Install the fuel tank onto the frame.
◇Roll up a throttle cable’s boot to expose an adjuster.

◇Attach a provided throttle cable to the lower throttle
housing.

Socketcap screws 6x25
◇Fix the cauburetor and inlet pipe with socketcap screws
6x25xand lock nuts.
Tool to use
Hex wrench, 5 mm
Open-end wrench, 10 mm
Caution: Apply the specified torque.
Torque: 10 N・m (1.0 kgf・m)◇Holding a hex nut, loosen the adjuster.
Tool to use
Open-end wrench, 8 mm
Open-end wrench, 10 mm◇Install the fuel tank onto the frame with a bolt.
Tool to use
Offset box wrench, 10 mm
Caution: Apply the specified torque.
Torque: 12 N・m (1.2 kgf・m)◇Connect an inner cable to the throttle pipe.

‑10‑Dec./13/ 12

18. Installation of seat.

CO◇Attach a side cover.

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

19. Installation of drive sprocket.
(on the engine side)◇Insert a seat-stay hook between two washers on therear shock absorber.

◇Fit a provided sprocket into the shaft.

Clip◇Detach a clip from the drive chain.

Masterlink

PY◇Install a provided plate, and tighten two bolts loosely fornow.

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

◇Attach a bolt and nut under the seat.
Tool to use
Socket, 12mm
Extension (short)
Offset box wrench, 12 mm
Caution: Apply the specified torque.
Torque: 22 N・m (2.2 kgf・m)◇Applying the rear brake, unfasten two bolts.
Tool to use
Socket, 10 mm
Extension (short)◇Remove a plate.

◇ 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)‑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.
★A hyper-S stage kit B type recommendation sprocket(In the case of 65kg weight)
Tire size

DrivesprocketClutchDrivensprocket

Ratio

CO
８
inc

１０
inc

Stock

１５

２５

１.６７

Strengthening, special

１６

２５

１.５６

Stock

１６

２５

１.５６

Strengthening, special

１６

２８

１.７５

◇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)

21．About a drive chain.

※When the sprocket is changed from the stock one to the recommended one, the drive chain may become short even if
adjusted. In this case, you need to prepare a drive chain separately and adjust the length. Moreover, the length of the chain◇Check for slack in the bolts and the like fixed all the way from the engine to the suspension.

varies according to the length of the swing arm. The list below is just for your 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

DrivenSprocketStock

４ｃｍ Stretch

８ｃｍ Stretch

１２(Stock)３１(Stock)７２(Stock)

−

−

−

−

１５

２５

７２

７６

８４

９０

９８

１６

２５

７２

７６

８４

９０

９８

１６

２８

−

−

−

９２

１００

１２ｃｍ Stretch １６ｃｍ Stretch◇Slack is checked for the bolts attached from the engine to the tire.
◇Attach the drive chain to the drive and driven sprockets.

マスタ
Masterlink
ーリンク

PY◇Turn on the fuel cock.

◇Fit the master link from inside to connect the drive chain, and attacha link plate.

Link plate

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
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 directionof driving.

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

Driving
direction

the flywheel aligns with the alignment mark on the crankcase.

Clip

Alignment mark“F” mark

Breaker-tightening
screw◇Fully tighten the loosely-installed drive sprocket bolt.
Tool to use
Socket, 10 mm
Extension (short)

Breakerplate

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.

22. Installation of crankcase left-side cover.
◇Install three bolts to hold a crankcase left-side cover.

Point gap: 0.3 - 0.4 mm
In case the gap is outside the limits, replace the point.

Tool to use
Cross tip screwdriver, (large)
Caution: Apply the specified torque.
Torque: 10 N・m (1.0 kgf・m)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‑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)

PY
5段目
5th
groove

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

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

○ Air screw

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

●On how the barometric pressure, temperatures and humidity affect the setting:・At highlands or at high altitudes, the barometric pressure and air density go down and the air gets into the carburetor in less amounts.
This makes the air-fuel mixture dense which was adjusted at low altitudes.
・Under the weather conditions with very low temperatures, the air density increases, which makes the air-fuel mixture lean.
・Under the rainy and humid weather conditions, the air density decreases, which makes the air-fuel mixture dense.
◎ Please be informed that, mainly because of improvement in performance, design changes, and cost increase, the product specifications andprices are subject to change without prior notice.
◎ This manual should be retained for future reference.
Co.,Ltd.
3-5-16 Nishikiorihigashi Tondabayashi Osaka Japan

TEL : 81-721-25-1357 FAX : 81-721-24-5059 URL : http://www.takegawa.co.jp
Aug./20/ 09