Hyper S-Stage V KIT Instruction Manual
Item No.
Applicable toFrame No.
０１―０５―０２３５ (Paper-type filter)
CRF50F：AE03-1400001 〜
０１―０５―０２３７ (Sponge-type filter) XR50R：AE03-1000001 〜
Thank you for purchasing one of our products. Please strictly follow the following instructions in installing and using the product. Before fitting the products,
please be sure to check the contents of the kit. Should you have any questions about the product, please kindly contact your dealer.
◎ Please note that, in some cases, the illustrations and photos may vary from the actual hardware.

CO

Cautions 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. In case regular gasoline is used, abnormal combusiton takes place, and the engine cannot achieve its
original performance. Moreover, it is highly likely that the piston will break down, leading to serious breakdown. Before installing,
make sure that no regular gasoline remains in the fuel tank. In case regular gasoline is remaining in the fuel tank, do replace itwith high-octane gasoline.

Cautions about spark plug

Please be sure to replace the spark plug with CR8HSA (NGK) or U24 FSR-U (DENSO). In the case of a non-resistive plug,
please replace with C8HSA (NGK) or U24 FS-U (DENSO).Subsequently, choose and use a right spark plug with the right level,
depending on the degree of burning of the spark plug electrode section.

Cautions about sprocket

The installation of this product will increase the power of your vehicle. So use of a stock sprocket will result in hard wears ofparts, not only adversely affecting the engine life, but also breaking the engine in the worst case. Please replace the sprocketwith the high-geared one.

PY

Read the instructions carefully before installation◎ We do not take any responsibility for any accident or damage whatsoever arising from the use of the products not in conformity with the instructions in
the manual.
◎ Installation of this product requires processing of the stopper part of the throttle pipe. Moreover, please note that the processing disables the use of anacceleration limiter.
◎ 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 alterations to the product outside our factory, we shall be held free from any guarantee of the product.
◎ You are kindly requested not to contact us about the combination of our products with other manufactureres'.
◎ This product is designed for exclusive use in the above-mentioned types of motorcycles and frame numbers only. Please take note that this productcannot be mounted on other types of motorcycles.
◎ Please install this product correctly, referring to the HONDA genuine service manual for the above-mentioned model numbers of the motorcycles.
◎Before installation, prepare tools and the like listed in page 2, and install the parts with utmost care, referring to the “Installation Procedures.” In addition,
this instruction munual as well as HONDA’s service manual is prepared with those in mind who have basic technical skills and knowledge. So,it isadvisable that those who do not have such tools, or skills or knowledge contact a technically reliable specialist shop for installation.
◎The supplied cylinder and cylinder head gasket differ from genuine ones in thickness. Please take note, these parts cannot be used in combination withother manufacturers’ parts as well as genuine parts. And please use our parts for repairs.
◎ A stock carburetor will interfere with the supplied cylinder. So, please process the interefering part in case you install a stock carburetor.
◎ Bolts, nuts, and dowel pins will be reused. However, be sure to replace worn-down or sevrely-damaged ones with new ones.
◎ You cannot run the motorcycle in the rain with kit’s filter installed. Otherwise, it could cause the engine trouble.
CAUTION The following show the envisioned possibility of injuries and damages to human bodies as a result of conduct 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 toyourself.)
・Always use a torque wrench to screw bolts and nuts tight and securely to the specified torque. (Otherwise, improper torque may result in the breakage
or coming off of bolts and nuts.)
・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.)※ Be sure to retighten the cylinder head to the specified torque.
・Please replace gaskets and packings with new ones withoutfail. Check carefully those parts to be reused, and in case wear or damage is detected,
always replace them with new ones.
WARNING The following show the envisioned possibility of human death or serious injuries as a result of conduct disregarding the following cautions
・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 ormaintence 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.)・Since gasoline is very ignitable, keep everything that may fire away. Also, since vaporized accumulation of gasoline has a explosion hazard, keepwell-ventilated place to work on.
‑1‑

Dec./17/ 12

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

Lesson◇ Bolts and nuts will get loose when turned counterclockwise,and tighten when turned clockwise.
◇In tightening screws, first finger tighten them as hard as possible without using tools. If they stop turning after giving them one or two turns, the screw
may be fixed at a slant.
◇ To loosen a screw means turning a tightened screw around three or four times counterclockwise, and to unscrew it means turning it 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◇ Contents of Kit

０１―０２―５１７
Piston kit

１

５

２

３
４

１２

１１

９

Parts' Name
PistonPiston ring set
Piston pin, 13 x 36
Piston pin circlip
CylinderCylinder gasket
Cylinder head gasket
Cylinder head cover gasket
R side cover gasket
L side cover gasket
Tappet cap O-ringExhaust pipe gasket
Rubber packing (black)
Camshaft
DENI18 carburetor assembly
Intake manihold

１６

１４

２３

２１

２２

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

Repair Part Item No.
13101-NSH-T00
01-15-014
13111-GEF-T01
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
01-08-0009
03-03-0061
17111-GBO-T00

２６

２５

２７

１９

No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

１５

７

１７

１８
２０

PY

１３

１０

８

６

２８

２４

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

No.

Parts' Name

Qty

17

Air filter (with a band)

1

18
19
20
21
22
23
24
25
26
27
28
29
30

Carburetor gasket
Inlet pipe gasket
6x20 socket cap screw
6x25 socket cap screw
710 mm throttle cable
Spark plug CR8HSA
Main jet #85
Drive sprocket, 15T
Tank spacer
Flange bolt, 8x25
Flange bolt, 8x30
Spacer, 8.2x10x9.5
Washer

1
1
2
2
1
1
1
1
2
1
1
1
1

２９

３０

Repair Part Item No.
in packs of
03-01-110 (Paper-type filter)1
03-01-1105 (Sponge-type filter)1
16201-GEY-T01
191301-181-T01
100-00-0043
1000-00-0089
10
09-02-0071
100-03-0041
02-05-022
16954-GEL-T00
00-00-0318
00-00-0181
00-00-0199
00-00-0201

1
1
1
5
4
4
6

※ 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./17/ 12

‑3‑Exhaust pipe gasket

Names of components※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

※1 Dowel pin, 8x12

Cam sprocket

Cam shaft COMP.

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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

CylinderBe sure to change to CR8HSA (NGK) or
U23FSR-C (DENSO).

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

※2
※3

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

※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

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Dec./17/ 12

Stock Parts Removal

3．Muffler Removal

2．Carburetor Removal

1．Exterior Parts Removal
A seat / shroud /rear fender assembly

Trim clip
Screw

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◇Remove carburetor’s top cap, and then take the throttle ◇Remove two nuts in the exhaust pipe.
Tool to use:
valve out from the carburetor.
10 mm open-end wrench

Bolts

7．Crankcase Left Cover
Removal◇Remove each two of trim clips, screws, and bolts
first, and then remove a seat / shroud / rear fenderassembly.

Inner pin◇Remove a storage tank hose.

◇Remove muffler stay’s bolts and then, the muffler.
Tool to use:
12 mm offset box wrench◇A trim grip can be removed by lifting an inner pin witha slotted screwdriver or other tools.
Tools to use:
10 mm offset box wrench

Slotted screwdriver (Midsize)◇Remove shift pedal’s hex bolt and then, the shift pedal.
Tool to use:
10 mm offset box wrench

PY
4．Front Fender Removal◇Remove the bolts on the air cleaner stay.
Tools to use:
10 mm socket
Extension bar (Small)◇Remove three bolts on the reverse side first, andremove the front fender.
Tools to use:

◇Turn off the fuel cock.

10 mm socket
Extension bar (Small)

5．Spark Plug Removal◇Remove three bolts which are fixing the crankcase
left cover.
Tool to use:
8 mm deep socket

8．Two Tappet Caps Removal◇Pull out the plug cap from the plug to remove it. Be sure
to hold the cap in pulling it out.

◇Shift the tube clip to disconnect the fuel tube.

◇Remove two bolts which are fixing the inlet pipe to the◇Remove two tappet caps.
◇Remove the plug with the in-vehicle spark plug wrench.
cylinder head. Then, remove the inlet pipe, theTool to use:
carburetor, and the air cleaner.
17 mm offset box wrench
Tool to use:
6．Cylinder Head Left Cover
8 mm offset box wrench
Removal

Bolt
CollarWasherFuel tank◇Install the earth wire on the frame with the bolts of air◇Detach a fuel hose from the carburetor, and then twobolts on the fuel tank to remove the tank.

cleaner stay.

◇By removing the hex bolt in the center of the right-side

Tools to use:cover of the cylinder head, you can remove the left cover.

10 mm socket
Extension bar (Small)(If you cannot remove the left cover in this way, screw inthe hex bolt by two to three screw threads, strike top of
the bolts lightly, and then you can remove the cover.)Caution: Apply the specified torque.

Tool to use:

Torque: 12 N・m (1.2 kgf・m)

10 mm socket‑4‑

Dec./17/ 12

9．Cam Sprocket Removal

13．Cylinder Removal

Guide roller bolt

Notch

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Side bolt

Marked “O”

切り欠き
Notch

◇Loosen the cylinder’s guide roller bolt and the side bolt
between the cylinder and the crankcase.
Tools to use:
10 mm open-end wrench◇Remove the already-loosened guide roller bolt and thecylinder side bolt.

◇Remove the piston pin, turning it in the direction inwhich the piston pin circlip has already been removed.
You can remove it easily by pushing it with a slottedscrewdriver from the side which still has a circlip.

10 mm offset box wrench

11．Cylinder Head Cover Removal.

Flywheel
フライホイール◇Pull and remove the cylinder. (When it is difficult, witha plastic hammer, strike a cylinder lightly and removeit.)◇Rotate the flywheel counterclockwise to alignflywheel’s “T” mark with the cam sprocket’s “O” mark.

◇Remove the piston.

PY◇Remove the four nuts, diagonally across the cover,which are used to fix the cylinder head cover.

15．Clearing Mating Surfaces◇Remove four washers under the nuts.
Tool to use:

10 mm socket◇Fix the flywheel and remove two cam sprocket’s hex
bolts.
Tools to use:
8 mm socket
14 mm offset box wrench (For flywheel fixing)

Cylinder gasket◇In the process of cylinder removal, a cam chain guideroller will come out, which do remove.

Rubber packing◇Remove a head cover. (If you cannot dismout the covereasily, remove the cover by striking it with a plastic

hammer lightly.) Completely get rid of the gasket
remaining on the cylinder head with a scraper or a cutter.

◇After the piston has been taken out, remove the cylinder
forward.

12．Cylinder Head Removal◇Remove the cam sprocket from the camshaft with a

14．Piston Removal◇Remove a cylinder gasket and a rubber packing.

slotted screw driver or the like by prising open the◇When gaskets do not come off completely, wipe themcam sprocket.
◇Remove the cam chain from the cam sprocket, andoff with a scraper or a cutter.

◇If the crankcase center gaskets stick out into thetake the cam sprocket out.
◇Remove the dowel pin which is stuck in the center ofcylinder base surface and / or cylinder hole, cut themoff.

the camshaft.

※Be careful not to let any foreign material into the

10．Cylinder Head Side Bolt
Removal.

◇Pull the cylinder head away from the cylinder to remove ◇Stuff a waste cloth into the crankcase’s cylinder hallit. (If it is not easy, strike it with a plastic hammer lightly.)
and the cam chain not to let any foreign material fall into

crankcase.

it.

Piston circlip◇Remove the cylinder head.
◇Remove the cylinder head side bolt(s) which are ◇Keep the two dowel pins for reuse.
used to fix the cylinder head and cylinder.

◇If gaskets stick out into the portion pointed by a thumb,cut them off. (See the picture above.)◇Remove one of the two piston circlips.
◇You can remove it easily by placing the end of a screw
driver at the notch on the piston pin hole and prising thecirclip open.
Tool to use:

Tool to use:
10 mm open-end wrench

A tapered slotted screwdriver‑5‑

Dec./17/ 12

Cautions to observe when
installing an aluminum cylinder

S - Stage Kit

Exhaust markInstallation

Due to the misalignment of the R andL crankcases and for other reasons, 1．Piston Installation
there may be interferance in sleevehole of the crankcase’s mating sur-CO

face, “O” mark, shaded areas of thecylinder sleeve, and inside the casewhen installing the cylinder. Sinceinterferance will lead to sleeve deformation and engine troubles, do not
fail to check and rectify the interfer◇Fit a piston pin circlip, attached to the left side of theence.

◇Install the piston so the arrow on the piston headpoints downward (exhaust side).

◇Attach the oil ring expander.

piston, in the circlip groove firmly.

◇At this point, fix the circlip so the circlip’s end gap does
not meet with the notch on the pin hole.
◇It is also an easy way to install it by inserting 1 / 3 of

Exhaust markthe piston pin into the piston.

Left◇Fit the kit’s piston pin circlip to the groove precisely.

side◇Attach the lower oil ring side rail.

PY◇It is relatively easy to install the circlip if you push it witha driver. But be careful not to damage the piston itself.

Tool to use:

A tapered slotted screwdriver◇It is relatively easy to install the circlip, if you push itwith a driver. But be careful not to damage the piston◇Apply engine oil to the ring grooves and install theitself.

piston rings in the following order: oil ring expander,
lower oil ring side rail, upper oil ring side rail, second※Push it with care because there may be a case where◇Attach the upper oil ring side rail.

ring, and top ring.

◇Arrange the piston rings so the ring-end gaps areto be in the correct positions as shown in the figure
below.

Modification Procedures
1．Stuff up cloth inside thecrankcase not to let any shaving
fall into it.
2．Rasp the convex surface on themating surfaces of the crankcase
till the surface becomes level.
3．Then, remove the waste clothwith care not to let swarf go
inside the case.
4．Then stuff up the case hole witha clean cloth.
5．Right after running the engine idle
for several minutes after the kit
assembly is over, exchange theengine oil for new one. Then, all
set.

the circlip is sent flying while you are pushing it.

◇Remove the cloth.

2．Cylinder Installation◇Degrease the cylinder and the crankcase sides of
the cylinder base gasket surface with thinner or

トTop
ップリング
ring
120°

something else.

120°

120°

Second
ring
セカンドリ
ング
エキスパンダー
ExpanderCylinder gasket◇Attach the second ring (black) with the engraved sideup.

Dowel pin

サイド
レール
Side
rails

60°

60°

Rubber packing (black)◇Make sure that two dowel pins B (12mm) are◇Attach the top ring (brown) with the engraved side up.

attached, and install a cylinder gasket and a rubberpacking (black).

“R” is engraved on the top ring
upper surface, and “RN” on thesecond ring counterpart.

Top ring
Second ring

◇Apply engine oil to the inside of kit’s cylinder, andSide rails

then spread the oil evenly with fingers.

Pistonン
ピスト
Expander
エキスパンダー

Take note of cross section◇Apply engine oil to the piston pin and con’rod, andinstall the piston pin.

‑6‑◇Install the cylinder.
Dec./17/ 12

CO◇Install stock cam’s dowel pin to kit’s cam.

◇To install the cylinder, press it little by little with
fingers carefully so the piston ring -end gap will not ◇Install a cylinder side bolt. (Temporarily tighten it justget out of position.
to the full extent possible with your fingers.)※This work is rather difficult. So do your best here!

Cylinder head
cover gasket

3．Camshaft Replacement◇Install the tappet screw of the rocker arm.
◇Install the cylinder head cover gasket and head cover.

◇After the rings are inside the cylinder, fit the cylinder

in the crankcase, passing the cam chain through thecylinder.

◇Remove the tappet nut and bolt on a rocker arm which
are installed to the cylinder head. Only after you haveloosened the tappet nuts, remove the tappet bolts
together with nuts.

Tool to use:
9 mm offset box wrench◇Pulling the cam chain, install the guide roller.

4．Cylinder Head Installation◇Degrease the head and the upper surfaces of thecylinder with thinner or the like.

PY

Pay attention to the arrow◇The arrow have to face down (EX side).

◇Attach a head gasket.

※A black rubber packing or green rubber gasket will not
be used.

Copper washer◇Attach head cover’s washers paying attention to theirpositions. (A copper washer has to be at the lower leftwhen the engine is seen from the front.)◇After installing the cam sprocket bolt to the camshaft,pull the camshaft or strike the head of the camshaft witha plastic hammer lightly. So, take out the camshaft,rotating it but without pulling it out by force.

◇Pass the cylinder head through the stud bolt.

◇Install it, passing the cam chain through the cylinder

Hex nuthead.

Oil application◇Install the head nuts paying attention to theirpositions (The hex nut has to be at the lower rightwhen the engine is seen from the front.)◇Push it so the center of the guide roller meets withthe cylinder’s guide roller bolt hole.

Oil application◇Apply clean engine oil to the cam and bearings of kit’s
camshaft.
◇Fix the cam chain by inserting a screwdriver into thehole in the center of the camshaft lest the cam chain
should fall down toward the cylinder.

◇Tighten up the head nuts evenly. (If you do not havea torque wrench, tighten them little by little
diagonally across the surface.)
Tool to use:
10 mm socket◇Install a guide roller bolt. (Temporarily tighten it justto the full extent possible with your fingers.)

Caution: Apply the specified torque.
◇Install kit’s camshaft in reverse order of that mentioned

Torque: 12 N・m (1.2 kgf・m)

above. Never strike it with a hammer even if you cannot
easily insert it. Just insert it by your hand.

‑7‑

Dec./17/ 12

6．Tappet Clearance Adjustment
Very difficult work. Do your best!

Notch

CO

Wipe off after tightening,bolt and cylinder side bolt which were temporarily
tightened.

◇After tappet adjustment, turn the flywheel

since a little oil comes out.

◇Install the head side bolt. Fully tighten the guide roller◇Remove the hex bolt next to the change pedal’s shaft.

Tools to use:

Thus, the cam chain’s tensioner, which is pulling at thecam chain, gets loosened; then you can easily install

10 mm open -end wrench
10 mm offset box wrench

the sprocket.

counterclockwise two times by hand, and then alignthe “T” and “O” mark with each other.

Engraved “O” markCylinder head side

Notch

◇Check for the alteration to the tappet clearance.
If altered, adjust again. If there is no change, it’s allright.

Flywheel side

◇Align the “O” mark on the camshaft and “T” mark on the
flywheel with each notch. Though the flywheel cannot
stop at the precise position due to magnetic repulsion,and the notch on the cylinder head meet each other, andit will be all set if “T” and “O” marks meet together after
then install it on the cam shaft.
installation of cam sprocket.

※This is a difficult work, so do your best here!
◇Fit the cam chain so the “O” mark on the cam sprocket

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Valve clearance(Intake side)◇After fitting the cam sprocket, install and tighten bolts.

Valve clearance(Exhaust side)

Adjustment screw

Caution: Apply the specified torque.

◇Install two tappet caps.
Tool to use:
17 mm offset box wrench

For guide roller bolt 10 N・m(1.0 kgf・m)
For upper and lower side bolts
10 N・m(1.0 kgf・m)

Caution: Apply the specified torque.

Torque: 12 N・m (1.2 kgf・m)
Thickness gauge
Valve stem
7．Cylinder Head Left CoverInstallation

5．Cam Sprocket Installation

Notch◇Fix the flywheel and tighten the two cam sprocket bolts.
Tools to use:
8 mm socket
14 mm offset wrench
Caution: Apply the specified torque.
Torque: 9 N・m (0.9 kgf・m)◇Align “T” mark on the fly wheel with the notch on the
crankcase.

◇Reinstall the hex bolt next to the change pedal shaft.
◇Set the camshaft so that cam’s top faces the pistonside when you turn the cam sprocket bolt hole to thecylinder head’s notch. The cam shaft is right at the
top dead center on the compression stroke.
※If you install the optional cam, follow the instruction
manual for the cam.

Tool to use:
10 mm offset box wrench
Caution: Apply the specified torque.
Torque: 10 N・m (1.0 kgf・m)◇Tighten a rocker arm’s tappet screw , and put in a 0.05
mm thickness gauge in between the tappet screw andthe valve stem end. And tighten a tappet nut securely tothe extent that you can pull out the 0.05 mm thickness
gauge only with a little resistence. (If you have no idea
about the right resistance in pulling out the gauge,
prepare a 0.07 mm and a 0.03 mm gauge. If the 0.07 mm
thickness gauge does not fit in between the tappet screw
and the valve stem end, and, at the same time, if you canput in the 0.03 mm gauge with almost no resistance,
this means that the clearance is about 0.05 mm. Adjust
the clearance at 0.05mm both at EX and IN sides.
Tools to use:
Needle nose plier
9 mm offset box wrench
Thickness gauge‑8‑◇Install the cylinder head L cover gasket and the L
cover. (Set the protrusion at the stopper so left-side
cover does not move right as the bolt is screwed.)
See the picture below.

(Set the protrusion at the whirl-stop.)Dec./17/ 12

10．Front Fender Installation

CO

Float pin

※Take note that the float pin will easily come off.
◇Remove the stock throttle cable from the lower throttle
housing.

Jet holder
Main jet◇Install the front fender with three bolts.
Tool to use:

10 mm socket
Extension bar (small)◇ Tighten the hex bolt (indicated by an arrow) on theright side of the cylinder head.
Tool to use:
10 mm socket

11．Throttle Cable Installation◇Take out the main jet from the jet holder.

◇Disconnect the wiring of the stock throttle cable.

Tool to use:
Slotted screw driver (middle size)◇Install kit’s throttle cable to the lower throttle housing.

Caution: Apply the specified torque.

Torque: 12 N・m (1.2 kgf・m)

8．Spark Plug Installation◇Loosen the hex nut.
Tool to use:

14 mm open-end wrench◇Install kit’s plug with in-vehicle tool or a spark plug
wrench.
Tool to use:
Spark plug wrench
Caution: Apply the specified torque.
Torque: 11 N・m (1.1 kgf・m)

PY◇Install kit’s main jet.

◇Connect it with the processed throttle pipe.

Tool to use:
Slotted screwdriver (middle size)◇Remove two screws, and take the upper throttle
housing out.

◇Install a plug cap to the plug.

9．Stock Muffler Installation◇Install the upper throttle housing with two screws.
※Tighten the front-side screw first, and then the
back-side screw.

◇Install the float chamber and install it to the
carburetor with two screws.

13．Carburetor Installation◇Remove throttle cable’s inner cable from the throttle
pipe.

Inlet pipe gasket

Stopper◇Install the muffler first, and then the bolt for the
muffler stay. (Temporary tightening)
Tool to use:
12 mm offset box wrench※In the case of a stock handle, align the divided part of
the throttle housing with the “O” mark as shown in the
picture above.
◇Wire the throttle cable.

12．Main Jet Replacement◇Place the inlet pipe gasket between the intake manihold
and the cylinder head, and install it with two 6x25 socket
cap screws.

Float Chamber

Tool to use:
5 mm hex wrench
Caution: Apply the specified torque.
Torque: 12 N・m (1.2 kgf・m)◇Tighten two nuts on the EX pipe side. (Temporary
tightening)
Tool to use:
10 mm open-end wrench◇Tighten fully those bolts and nuts which were
temporarily tightened.
Caution: Apply the specified torque.
Bolt 26 N・m(2.7 kgf・m)
Nut

10 N・m(1.0 kgf・m)

Screw◇Take a throttle pipe out from the handle, and process◇Remove two screws first, and then, a float chamber.

and remove the stopper of the throttle pipe as shownin the pictures above.

‑9‑

Tool to use:
Cross chip driver (middle size)
Dec./17/ 12

Carburetor
gasketCO

Bolts◇Install the storage tank hose to the air filter.

◇Join the concave section of the carburetor and the◇Place the carburetor gasket between the carburetor
and the intake manifold, which please fix with two 6 x
20 socket cap screws.

convex section of the top cap together.

Screw (L.R.)

14．Throttle Free Play Adjustment

Tool to use:
5 mm hex wrench

Caution: Apply the specified torque.

Torque: 12 N・m (1.2 kgf・m)◇Connect a fuel tube to the carburetor.

16．Exterior Parts Reinstallation◇Pull down the boot at the tip of the throttle cable toBolt 8X30

expose the adjuster.

Trim clip (L.R.)

PY
Stock collar

Tank spacer

Bolt 8X25◇Hold the hex nut and loosen the adjuster.
Tools to use:

◇Remove carburetor’s top cap, and take out the spring
and the throttle valve.

8 mm open-end wrench
10 mm open-end wrench◇Attach two pieces of bolts, screws, and trim clips

WasherThrottle cable
遊びが多く
Moreなるplay
アジャスターCollareach.
Tools to use:
10 mm offset box wrench
Cross chip screwdriver (middle size)
Caution: Apply the specified torque.
for bolts
10 N・m (1.0 kgf・m)
for screws

4 N・m (0.4 kgf・m)Tank spacer

adjuster

六角ナット
Hex nut

Less◇Place a tank spacer between the fuel tank and frame at
the front part of the fuel tank and fix it with a bolt. And at
the rear part of the fuel tank, place a tank spacer between
the frame and fuel tank, and put a collar and a provided
washer to fix a bolt.

◇You can adjust the free play by rotating the adjuster.

about 5 mm

Caution: Apply the specified torque.

Torque: 26 N・m(2.7 kgf・m◇Insert the claw at the backside of the seat into the hookon the frame, and install an assembly of a seat, shroud
and rear fender with each two pieces of trim clips, screws
and bolts.
※Pulling the shroud, align the mounting holes withthe screw holes on the fuel tank to put in two screws.

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

◇Fix an adjuster and screw a hex nut tight.
Tools to use:
8 mm open-end wrench
10 mm open-end wrench◇Turn the throttle to check that the throttle valve moves
smoothly.
◇Check that the throttle has certain free play even when
you turn the handle all the way to left and right.

In case you cannot easily put in the screws, file down
the holes to elongate them.

Hooks
Buckle◇Put back the boot in its original place.
◇Install the top cap to the throttle cable, attach thespring, and install the throttle valve to the inner cable.

15．Air Filter Installation

Notch
Throttle
stop
screw

◇Insert the claw at the backside of the seat into the hookon the frame, and install an assembly of a seat, shroud
and rear fender.

Co.,Ltd.
3-5-16 Nishikiorihigashi Tondabayashi Osaka Japan◇Placing the throttle valve notch in the direction of the ◇Install a band to the air filter and insert it into thethrottle stop screw, put it in the carburetor to fix it.
carburetor. Tighten the band.

TEL : 81-721-25-1357 FAX : 81-721-24-5059 URL : http://www.takegawa.co.jp‑10‑Dec./17/ 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