S-Stage Bore Up Kit 106cc SCUT Instruction manual
Product number

01-05-5311
01-04-0117(Cylinder Kit)

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

Monkey & Gorilla (Z50J-2000001 ～ )(AB27-1000001 ～ )CD50(CD50-1500001 ～ )CL50(CL50-4000001 ～ )Super cub 50(C 50-9000001 ～ 0095210)(C 50-0200001 ～ 0999999)(C 50-2100001 ～ 2299999)
Adaptation model(AA01-1000001 ～ 1699999)
Little cub(C 50-4300001)(AA01-3000001 ～ 3699999)
Dax(AB26-1000001 ～ )CRF50F(AE03-1400001 ～ )XR50R(AE03-1000001 ～ )CO

About fuel to use

This S-Stage Kit is so designed to achieve a higher compression ratio than stock engines. Therefore, high-octane gasoline should
always be used. In case regular gasoline is used, you cannot get the performance of this Kit. Moreover, it is possible that thepiston 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 the fuel tank, do replace it with high-octane gasoline.

About the spark plug

Be sure to replace a spark plug with a CR8HSA (NGK) or U24FSR-U(DENSO). In the case of a non-resistive plug, please replace with C8HSA (NGK)or U24FS-U (DENSO). Subsequently, choose and use a right spark plug with the right grade, depending on the carburetor set up.

About quick starting and sudden acceleration

Please note that idling, sudden acceleration, and sudden engine braking will put a heavy load on the engine, and that it may resultin crank shaft and engine damages in the worst case.

Important notice about installation of this Kit

A heavy-duty clutch（the one with three friction disks）and heavy-duty oil pump are needed for the installation of this kit.
(Monkey/Gorilla/CD/DAX/CRF50F)
For the installation of this Kit, a heavy-duty centrifugal clutch (with 32 weights) and heavy-duty oil pump are needed.(Cub 50/Little cub)※ We disclaim all responsibility for consequential and incidental damages or any other losses arising from the use of the Kit,
if your bike is not equipped with these additional hardware.

☆ Please read carefully before use ☆

PY◎ We do not take any responsibility for any accident or damage whatsoever arising from the use of the Kit not in conformity with the
instructions in this Instruction Manual.
◎ Please drive safely and follow the local traffic law.
◎ We shall be held free from any kind of warranty whatsoever of products other than this product if the glitch takes place on theother products than this one after the installation and use of this product.
◎ We do not have any information or service data on the combination of our products and other manufacturer’s products.
◎ 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 tools and work with reference to the installation procedures. Besides, this instruction manual, as
well as a genuine parts service manual,is prepared for persons who have acquired basic skills and knowledge. We recommend those who
are technically inexperienced or without enough tools to ask a technically-reliable specialist shop for the installation work.
◎ 01-04-0117 (cylinder kit) must be used with Takegawa’s super sports camshaft. Please note.
◎ Bolts, nuts and dowel pins will be reused. However, be sure not to use the worn-down or severely-damaged ones, which please do
replace with new ones.
◎ If you use a stock carburetor, do not remove the air cleaner box or 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.
◎ In some cases noise coming from the cylinder may sound louder than stock.
◎ This Instruction Manual is prepared mainly for the Monkey. Therefore, this Instruction manual has some contents not to apply to other vehicles.
◎ Always use the supreme unleaded high-octane gasoline.
◎ We recommend to install and use an oil cooler for riding at a high outdoor air temperature.
◎ We highly recommend to upgrade the exhaust system and the carburetor to ensure the potential even though the stock exhaust systemand stock carburetor are fine to ride.

～ feature ～○ The incorporation of a cam shaft with a decompressor mechanism reduces the load on the transmission and kick shaft even on a 106cc
engine, made possible, for example,by S-Stage (SCUT) Bore Up Kit, leading to start of engine only with lighter kicking power than
before. Cylinder has an oil jet hole, which can lubricate and cool the piston and the connecting rod.
CautionWhen the handling of ignoring this display, property damage and human shows the assumption of what injury.

■ Please drive safely and follow the local traffic law.
■ Work only when the engine and exhaust system are cool to avoid burns.
■ Prepare appropriate tools and work properly to avoid the breakage of parts or injuries.
■ Always use a torque wrench to tighten bolts and nuts securely to the specified torque to avoid these parts getting damaged or loose.
■ As some products and frames have sharp edges or protruding portions, work with your hands protected to avoid injuries.
■ Before riding, always check such parts as screws for loose. If you find loose ones, screw them securely up to the specified torque to
avoid parts coming off.
■ Always use new gaskets and seals. About the reused parts, please check carefully for wear or damage and be sure to replace them withnew ones if necessary.
CONTACT Address : 3-5-16 Nishikiorihigashi Tondabayashi Osaka JAPANTEL: +81-721-25-1357 FAX:+81-721-24-5059 e-mail:english@takegawa.co.jp URL http://www.takegawa.co.jp
Please contact with your name and country name provided. (Only English please)2022.2.24

01-05-5311,01-04-0117

/13

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

Warning■ 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, stop riding immediately and park your motorcycle in a safe place to avoid
an accident.
■ Before working, place the motorcycle on level ground to stabilize its position for safety to avoid the motorcycle overturning.
■ 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 inspecting or performing maintenance of your motorcycle, do not use these parts, and replace them withnew ones. (The continued use of these damaged parts could lead to accidents.)■ As gasoline is highly flammable, never place it close to fire. Make sure that nothing flammable is near the gasoline. Since vaporized
accumulation of gasoline is at high risk of explosion, work in a well-ventilated place. (Otherwise it may cause a fire.)◎ Please note. Performance up, the design change, the product and the price in the cost up, etc. are subject to change without notice.
◎ Please be informed that we shall be held harmless against any claim against us whatsoever arising out of use of the products in
racing and the like.
◎ Keep this manual stored until this product is discarded.

LessonCO◇ Bolts and nuts will get loose when turned counterclockwise, and tighten when turned clockwise(some exceptions).
◇ At the beginning, hand tighten a screw without using a tool until it stops. If it stops turning after giving it one or two turns,
the screw may be fixed improperly.
◇ To loosen a screw means turning a tightened screw three or four times to the counterclockwise, and to remove it means turning it
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 breakor get loose when tightened is the so-called “torque.” If you do not have a torque wrench, please try to tighten a screw as tightas 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 atwhich the bolt will break or get loose.
◇ Improper use of tools will result in breakage of a top of a bolt or screw.

5

01-02-0127
1
3 4

Product content

PY

01-13-0606

6

2

13

15

01-13-0607

01-13-7002
11

7

10

8

12
14

16

9

NumberProduct content
Quantity
Item Number
NumberProduct content
Quantity
Item Number
12 Exhaust pipe gasket
1
Piston1
100-01-0064 (2 pcs)
13 Rubber seal
2
Piston ring1
13012-RAS-T00
1
00-01-0066 (2 pcs)
14 Inlet pipe gasket
3
Piston pin
100-01-0091 (with clip)
1
91301-181-T01
15 Camshaft COMP.
4
Piston pin circlip
200-01-0003 (6 pcs)
1
01-08-0009
16 Mark set
5
Cylinder
101-01-0220
1
TS-001-001
6
Cylinder head gasket
1
12251-GFL-T10※ Please order in the repair parts are always repair part number.
7
Cylinder gasket
100-01-0067 (2 pcs)
If it is not the part number order, you may not be able to order.
Please be forewarned.
8
Head cover gasket
1
It should be noted, In the case of parts that can not be
01-13-7002
9
Right-side cover gasket
1
separately shipment,please order a set part number.
10 Left-side cover gasket(O-ring 2 pcs)
1
※ Part Nos.15 and 16 are not included in the Cylinder Kit of
11 Tappet cap O-ring2
Item No. 01-04-0117.

◇ Tools to use for the installation
1
2
3
10

4

11

5
6
7
8
9
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12

13

14
15
16

17 18 19
20

1
2
3
4
5
6
7
8
9

Torque wrench
Plastic hammer
Cutter knife
Open-end wrench, 8-10
Open-end wrench, 12-14
Open-end wrench, 14-17
Offset box wrench, 8-10
Offset box wrench, 12-14
Offset box wrench, 14-17
Spark plug wrench handle
10(in-vehicle tool）

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Spark plug wrench(in-vehicle tool)
12 Needle-nose plier
13 Thickness gauge
14 Fine-shaft flat tip screwdriver
15 Extension (medium)16 Extension (small)
17 Socket, 14mm
18 Socket, 12mm
19 Socket, 10mm
20 Ratchet wrench
112022.2.24

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Exhaust pipe gasket

Tappet adjusting hole cap

O-ring, 30mm
Camshaft

Left-side Cylinder headside cover gasket
Left-side Cylinder headside cover

Knock bolt, 5mm

Dowel pin, 8x12 ※ 1

Cam sprocket

Dowel pin, 8x14 ※ 1

Cylinder head gasket

Inlet pipe gasket

PY

Cylinder head cover gasket

Hex nut,, 6mm

Sealing washer A, 6 mm
(Copper plated)

Cap nut, 6mm

Sealing washer, 6mm

Cylinder head cover

Stopper plate

Valve rocker arm

Tappet adjusting screw

Tappet adjusting nut

Valve rocker arm shaft

Flange bolt, 6x20

O-ring, 30mm

Tappet adjusting hole cap(Copper or a aluminum)
sealing washer, 6.5 x12

Flange bolt, 6x110

Spark plug ※ 3

※2

※3

※2

※1

Bolt, 6mm

Cam chainguide roller COMP.

Dowel pin, 8x14 ※ 1

Bolt, 6mm

washer, 8mm

Guide roller bolt

Dowel pin, 8x12 ※ 1

Cylinder gasket

Rubber seal, 16mm

PistonPiston pin

Piston pin clip

Piston ring set

CylinderThere are several kinds of length for dowel pins.
Please make sure of the size before installing.
These hardware is not included in the kit orwill not be used for the installation of this kit.
Be sure to use CR8HSA (NGK) or U24FSR-U (DENSO).

CO

Right-side Cylinder headside cover

Right-side Cylinder headside cover gasket

Part names

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

Removal of standard
hardware
1.Remove the carburetor(Monkey)◇ Turn off the gasoline cock at
the lower left of thegasoline tank.

(Cub)◇ Unfasten a nut A (12mm cap nut),and bolts B and C (10mm bolts),
by turning them counterclockwise.
And unfasten washers and thelike at the same time.
Do the same to the left side
as well.

◇ Remove the horn stay.

◇ Detach two collars of theflange and then remove theexhaust system from the
motorcycle by pulling it
outwards.

C◇ Remove the belt bundling wires.
A
B

CO◇ Disconnect the fuel and air
hoses.

◇ Turn off the gasoline cock at
the lower left of the carburetor.

Fuel hose◇ Remove the carburetor ASSY.
attached with throttle cables
and choke cables and hang on
the front-left turn signal.

◇ Remove the fuel cock by turning
two screws counterclockwise.

Air hose◇ Disconnect the hose on thestorage tank in the case of
bikes with frame Nos AB27-.

2.Remove the exhaust system(Monkey)◇ Remove two nuts on the exhaust
pipe by turning themcounterclockwise.

PY

(Cub)
◇ Remove two nuts on theexhaust pipe by turning themcounterclockwise.

◇ Remove two bolts by turningthem counterclockwise which holda cylinder head and inlet pipe.

◇ Remove the nut which holds theexhaust system, by turning it
counterclockwise.

◇ Loosen the bolt on the aircleaner bracket.

◇ Remove the nut which holds
the exhaust system, by turning
it counterclockwise.

◇ Remove the duct by pulling upward.

◇ Turn a nut, fixed at thereverse side of the exhaustsystem, counterclockwise toremove it.

◇ Remove two bolts holding thecylinder head and inlet pipe.
◇ Remove bolts on both right andleft sides of the air cleaner by
turning them counterclockwise.

◇ Hang a carburetor assembly
onto the turn signal in thefront on the left, with thethrottle cables connected.
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/13◇ Remove the exhaust system bypulling outwards.
Do not lose the exhaust pipe
gaskets.

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

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

◇ Turn three bolts counterclockwise
which hold the generator cover.

Notch

9.Remove the cylinder-headside bolt◇ Remove the cylinder-head sidebolt, which holds the cylinder
head and cylinder, by turning
it counterclockwise.

“T”mark

With electric starter models◇ With electric starter models,
remove both A and B by turning
counterclockwise.

CO

4.Remove the spark plug

◇ Remove the plug cap from theplug by pulling it out.
Be sure to hold the cap inpulling it out.
◇ With an in-vehicle tool of aplug wrench, turn the plugcounterclockwise to remove it.

With electric starter models“T”markA◇ Holding the flywheel,remove twohex bolts on the cam sprocketby turning them counterclockwise.

B◇ Loosen the guide roller bolton the cylinder and the sidebolt between cylinder andcrankcase by turning themcounterclockwise.

Guide roller bolt

7.Remove two tappet caps
Side bolt◇ Turn two tappet caps
counterclockwise to removethem.

5.Remove the cylinder-head
left-side cover.

◇ The left-side cover will become
separated when the hex bolt inthe middle of the cylinder-headright-side cover is removed.
In case the left-side covercannot be detached by so doing,screw in the hex bolt by a few
threads, and strike the bolt
head with a hammer lightly.
Then the bolt will get separated.

8.Remove the cam sprocket

PY
With electric starter models◇ Turn four nuts counterclockwise,
which hold the cylinder-headcover, alternately anddiagonally to remove them.
◇ Remove four washers beneathnuts.

◇ Turn the flywheel counterclockwise
so a “T” mark on the flywheel
and “O” mark on the cam
sprocket align with their own
notches.
Notch

Stamped“O”mark

○

Bolt

○○

◇ Prize the cam sprocket fromthe camshaft with a small-sized
flat tip screwdriver to removeit.
◇ Detach the cam chain from thecam sprocket, and remove thecam sprocket.
◇ Detach the dowel pin fixed in
the center of the camshaft.

Cam sprocket

6.Remove the generator cover◇ Remove the hex bolt on the shiftpedal, and turn the shift pedal
counterclockwise to remove it.

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10.Remove the cylinder
head cover

/13◇ Remove the head cover. (If it
does not come off easily,
strike it lightly with aplastic hammer, and it will
come off.) If some gaskets
remain on the cylinder head,wipe them off completely witha scraper or a cutter.

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

11.Remove the cylinder head ◇ Pull out the cylinder. (If it(Monkey)◇ To make work space, let air
out of a front tire.
(At the press of the valve withsomething like a tip of a crossslot screwdriver, the tire will
deflate. Continue pressing ittill the whoosh of air cannot
be heard any longer.)◇ Remove the cylinder head fromthe cylinder by pulling thehead away from the cylinder.
(If it does not come off easily,
strike it lightly with a plastic
hammer, and it will come off.)is hard to pull it out, hit thecylinder lightly with a plastic
hammer.)◇ While removing the cylinder,
the cam chain guide roller will
come out, which please remove.

CO◇ Pressing the front tire,remove the cylinder head.
Now you can see the reason
why you have let the air outof the tire.
◇ Remove and keep the two dowelpins to reinstall.

◇ Remove the piston.

◇ Remove the loosened guide rollerbolt and cylinder side bolt by
turning them counterclockwise.

1.Assemble and install apiston※ Arrange the position of apiston pin circlip end-gap
not to be on the notch.

◇ Fix a supplied piston pin
circlip securely to thegrooves for circlip on one
side of the piston. Be sure
to set a circlip so its end
gap is not on the notch.

Notch in the piston hole
Circlip end-gap

14.Remove a cylinder gaske
rubber seal and dowel pin◇ In case you cannot remove all
the gaskets completely,rasp or
wipe them off with a scraper orsomething else, exercising great
caution not to scratch thecrankcase.
In case the crankcase center
gaskets squeeze out into thecylinder base, cut them off.
Never let any dirt, dust or
hardware into the crankcase.

◇ You can rather easily install
the piston pin circlip bypressing
it with a screwdriver, but
taking care not to damage thepiston with the screwdriver.
◇ Fix the piston pin circlip
first on the left side.

PY◇ Plug the cylinder hole in the
crankcase with a waste cloth soas never to let the dirt, dustor hardware into the cylinderhole and cam chain.

Cylinder gasket

Rubber seal

12.Remove the cylinder

Installation of S-Stage Kit

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

13.Remove the piston(Cub)◇ Remove the cylinder head fromthe cylinder by pulling thehead away from the cylinder.
(If it does not come off easily,
strike it lightly with a plastic
hammer, and it will come off.)◇ Remove and keep the two dowelpins to reinstall.

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

◇ Remove one of the two piston
pin circlips. You can remove itby prising it open with ascrewdriver tip being placed on
the notch.

Exhaust mark
Left
side

◇ Apply engine oil to thepiston-ring grooves, and fix
piston rings in the order ofan oil ring expander, lower
oil ring side rail, upper oil
ring side rail, and top ring.
◇ Arrange the positions ofpiston ring-end gaps so theymesh with each other.
Top ring

120˚

120˚

Side
rails
Expander60˚

60˚

15.Installation of clutch
and oil pump
Piston pin circlip

2022.2.24

01-05-5311,01-04-0117※ In using this kit are required
an oil pump and heavy-duty
clutch.
※ Installation of the oil pumpand the clutch at this stage isquite easy.

/13

Top ring
Side rails
PistonExpanderPay attention to the crosssection as well

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

◇ Put the oil ring expander.

◇ Fix the piston so the arrow on
the piston head faces downward,
or to the exhaust side.

◇ Check that two dowel pins arepresent.

◇ Press in the guide roller so
the center of the guideroller and the guide-rollerbolt hole on the cylinder.

Exhaust mark
Dowel pin

◇ It will also be an easy way of
installing the piston to first
insert the piston pin about one
third into the piston.

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

◇ Put the lower oil ring siderail.

◇ Put the upper oil ring siderail.

◇ Insert the cylinder.

◇ Fix securely the supplied
piston pin circlip to thecirclip groove.
◇ You can rather easily install
the piston pin circlip bypressing it with a screwdriver,
but taking care not to damage
the piston with the screwdriver.
Do the work carefully as,
in some cases, the circlip comes
off flying while you are pressing
it inside. So, wear protective
eyeglasses for your eyes.

◇ Put the top ring.

◇ Install the guide roller bolt.
(Fasten it only finger tightfor now at this point.)

PY◇ Fit in the cylinder, byinstalling the piston rings one
by one with fingers, being careful
not to move the piston ring-end
gaps out of place.

◇ Attach the cylinder side bolt.
(Fasten it only finger
tight for now at this point.)◇ Remove the plugged waste cloth.
◇ Apply engine oil to the piston
pin and to a small end of the
con’rod, and install the piston
pin.

2.Installation of cylinder◇ Degrease the mating surfacesof the cylinder and the
crankcase to attach the gasket.
◇ Install the cylinder gaskets
and rubber seal.

◇ Once the piston has been placed
inside the cylinder,pass the cam
chain through the cylinder, and fix
the cylinder into the crankcase.

◇ Pulling the cam chain, fix theguide roller.

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/13

3.Change of camshaft◇ Loosen tappet adjusting nuts
and tappet adjusting bolts on
the rocker arm in the cylinder
head. At the time the tappet
adjusting nuts are loosened,
detach the tappet adjustingscrews as well.

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

◇ Install the cam-sprocket bolt
into the camshaft. The camshaft
will come out when you pull it
out or strike its head lightly
with a plastic hammer. Turning
the camshaft, detach it.
Do not pull it out by force.

◇ Install the head gaskets.

◇ Attach head-cover washers andnuts.
(With engine viewed from thefront, attach the copper washer
and three iron washers at thelower left, and hex nut andthree cap nuts at the lower
right.)◇ Install the cylinder head
while fitting the cam chain andstud bolts in place.

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

◇ Passing the cam chain throughthe cylinder head,install thecylinder head.
◇ Hold the cam chain by sticking
the screwdriver through the cam
chain into a middle hole on thecamshaft so the cam chain will
not fall into the cylinder.

◇ Attach a dowel pin on a stock
cam to the supplied cam.

◇ Tighten the head nuts evenly.
(If the torque wrench is notavailable, tighten them bit by
bit securely and diagonally.)
Note: Be sure that you protect
specified torque.
Head nut

Hex nut

Notch

T markWith electric starter models◇ Install the tappet screw on
the rocker arm by turning it
clockwise.

MO-OIL◇ The arrow should face downward.

◇ Attach a head side bolt.
Fully tighten the guide roller
bolts and the cylinder sidebolts which were tightened
temporarily.

4.Installation of cylinder
head

2022.2.24◇ Align the “T” mark on the
flywheel with the notch on the
crankcase.

PY
Torque：12N・m（1.2kgf・m）◇ Attach the cylinder-head covergaskets and head cover.

◇ Degrease the cylinder headsurface and upper surface ofthe cylinder.
◇ Fix two dowel pins into thecylinder.

5.Installation of cam
sprocket

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

Arrow showing which sideshould face downward.

Torque：10N・m（1.0kgf・m）
Lower and upper side bolts

Torque：10N・m（1.0kgf・m）

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/13

T mark◇ Set the shaft so the cam top
faces the piston when the cam
sprocket bolt hole is turned
toward the notch on the cylinder
head. This arrangement places
the cam shaft at TDC (Top Dead
Center) on the compression
stroke.
※ In installing the optional cam,please refer to its instruction
manual.

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

◇ Remove the hex bolt next tothe change-pedal shaft.
（As the tensioner, guiding
the cam chain, will slacken,
it will be easy to install
the cam chain.）◇ Install the hex bolt which wasnext to the change pedal andwas just removed.
Note: Be sure that you protect
specified torque.
Bolt

Torque：10N・m（1.0kgf・m）

Change-pedal shaft
Oil will flow out a little after
the bolt is tightened. Wipe off
the oil.

CO◇ Attach the cam chain to thecamshaft so the “O”mark on
the cam sprocket and thenotch on the cylinder headmesh together.

◇ While tightening a rocker arm's
tappet adjusting screw,tighten
the tappet adjusting nut to theextent that a 0.05mm thickness
gauge, placed between the tappet
adjusting screw and the valve stem
end, can be pulled out with only
a little resistance.If you haveno idea of the proper resistancein 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 gaugegoes in quite loosely,this meansthat roughly 0.05mm clearance
is secured.

Stamped“O”mark○

Torque：9N・m（0.9kgf・m）

Bolt

○○

Cam sprocket

7.Installation of cylinder
head left-side cover
Valve clearance(Exhaust side)
Adjusting screw◇ Attach the cylinder-head
left-side cover gaskets andleft-side cover.
（Set the anti-rotation stopperof the left side cover toprevent the left-side coverfrom turning to the right when
the bolt is being tightened.）

PY
Thickness gauge
Valve stem

Cylinder head side
Notch

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

T markFlywheel side

With electric starter models

Set the protrusion at theanti-rotation stopper◇ Tighten up a hex nut at theright side of the cylinderhead.
(The arrow marked nut is thehex nut in the above photo.)
Note: Be sure that you protect
specified torque.
Hex bolt

With electric starter models

Torque：12N・m（1.2kgf・m）

T mark2022.2.24

Torque：12N・m（1.2kgf・m）

6.Valve timing adjustment
and tappet clearance
adjustment

Notch

Note: Be sure that you protect
specified torque.
Cam sprocket bolt

Note: Be sure that you protect
specified torque.
Tappet cap

Valve clearance(Intake side)◇ Turn the flywheel until the“O”
mark on the cam shaft and the“T”mark on the flywheel meshwith each notch.
Though the flywheel will notstop right at the required
position because the magnet
force repels each other,it is
all right if ”O”and“T”marks
mesh with each notch at thesame time.

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

◇ Install two tappet caps.

01-05-5311,01-04-0117◇ Check if there is any change
in the tappet clearance.
If the clearance has not changed,
there is no need to readjust it.
However, in case there is achange,readjust the clearance.

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

8.Installation of spark plug ◇ At this point, loosely install◇ Install the plug with either anin-vehicle tool or plug wrench.

a hex bolt which holds theexhaust system.

Note: Be sure that you protect
specified torque.
Plug

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

Torque：11N・m（1.1kgf・m）

Torque：26N・m（2.7kgf・m）

CO◇ In installing the exhaustsystem, route the tail pipe
inside the rear shock absorberfirst, and then run the flange
close to the exhaust outletof the cylinder head.

◇ Fully tighten the loosely
tightened nuts and bolts atthree portions.
(Cub)◇ Fit the exhaust system between
the brake pedal and step andset the flange under the exhaust
port of cylinder head.
◇ Set the exhaust pipe gasket
into the space between thecylinder head and exhasut
system. Hand tighten the nut
temporarily to fit the exhaustsystem to the pivot shaft.

◇ Install two flange collars,squeezing the exhaust pipe.

◇ Attach fuel and air hoses.
Fuel hose(Monkey)◇ In the case of vehicle withframe Nos Z50J-, check that an
O-ring is attached to the inlet
pipe.

◇ Attach two bolts which holdthe cylinder head and intake
manifold.

◇ Attach a plug cap to the plug.

9.Installation of stock
exhaust system

10.Installation of stock
carburetor

Note: Be sure that you protect
specified torque.
Bolt

Air hose(Cub)

Torque：10N・m（1.0kgf・m） ◇ Make sure the O-ring isinstalled on the inlet pipe.

◇ Install a bolt on the aircleaner bracket, fastening thebolt and earth jointly at thesame time.
（See the figure below）

PY
Note: Be sure that you protect
specified torque.
Bolt◇ Bundle the choke cable andmain harness.
Choke cable

Torque：10N・m（1.0kgf・m）◇ Tighten two nuts on the exhaust
pipe loosely for now.

◇ Tighten two nuts on the exhaust
pipe loosely for now.

◇ Mount the air cleaner on theframe with one bolt each on
right and left sides.

Note: Be sure that you protect
specified torque.
Nut

Torque：10N・m（1.0kgf・m）

Air cleaner bracket◇ Tighten the nuts to hold theflange and vehicle.

Earth

Note: Be sure that you protect
specified torque.
FlangeTorque：10N・m（1.0kgf・m）
VehicleNote: Be sure that you protect
specified torque.
Bolt

Torque：10N・m（1.0kgf・m）

Frame

Torque：36N・m（3.5kgf・m）◇ Attach a nut on the reverse sideof the muffler loosely for now.

Bolt

◇ In the case of vehicle withframe Nos AB27-. install thehose of the storage tank.

Note: Be sure that you protect
specified torque.
Nut

Torque：10N・m（1.0kgf・m）◇ Fully tighten the loosely
tightened nuts and bolts atthree portions.

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Main harness

01-05-5311,01-04-0117

10/13◇ Install the duct.

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

◇ Fasten two bolts of theintake manifold.
Note: Be sure that you protect
specified torque.
Bolt

Torque：10N・m（1.0kgf・m）◇ For an electric starter model,tighten both A and B.
Note: Be sure that you protect
specified torque.

A：2N・m（0.2kgf・m）
B：3N・m（0.3kgf・m）

With electric starter models

A
B

CO

◇ Connect wires to the horn.

◇ Attach the change pedal.
Note: Be sure that you protect
specified torque.
Change pedal

Torque：10N・m（1.0kgf・m）

12.Installation of leg shield(Cub)◇ Fit the backside of the leg
shield on the frame and thenthe front side.
◇ At the portion A, tighten the
12mm cap nut, placing theplate in between the nut andleg shield.
At the portion B, tighten the
10mm long bolt, placing thespacer between the rear side ofthe leg shield and the longbolt.
At the portion C, tighten the
10mm bolt, placing the washer
in between a mounting point andthe 10mm bolt.
Do the same on the other side.
Note: Be sure that you protect
specified torque.

A：20N・m（2.0kgf・m）
B、C：10N・m（1.0kgf・m）
C◇ IInstall the fuel cock with
two screws.

A
B

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12.Install the front fender(Monkey)◇ Fasten two hex bolts on thereverse side of the front fender.

◇ Turn on the fuel cock.

A

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

Torque：10N・m（1.0kgf・m）

B

11.Installation of generator
cover◇ Pump the tire.

◇ Install three bolts to holdthe generator cover.
Note: Be sure that you protect
specified torque.
Bolt

Torque：10N・m（1.0kgf・m）

C◇ Check for slack in the bolts
and the like fixed all the way
from the engine to the suspension.

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

● Before riding
1 About fuel◇ High-octane gasoline should always be used.
◇ If there remains regular gasoline in the fuel tank, always replace it with high-octane gasoline.
◇ Please use this kit at STD.ignition timing. Please note that we hold no responsibilities for accelerating the ignition timing.

2 Additional hardware to be installed◇ For driving your bike with this kit installed, the following hardware need to be installed additionally.
We disclaim all responsibility for any consequential and incidental damages or any other losses arising from the use of the provided
products or parts, if your bike is not equipped with these additional hardware.

2-1 Oil pump
The installation of this kit increases the heat release value of the engine, set off by the increase in power. The installation ofSuper Oil Pump is essential in order to circulate large amounts of oil and to help cool hardware and to alleviate the burden.

COEssential Super Oil Pump
Models12V Monkey and Gorilla
Benly CD50/CL50/50S
12V DAX
XR50R/CRF50F
Super cub 50
Little cubPart No.

01-16-0053（with drill bit）
01-16-0052（without drill bit）

2-2 Clutch

The stock clutch cannot respond to the high engine power, and, therefore, causes clutch slippage, and consequently cannot transmit theengine power fully to the driving side.
Therefore, it is necessary to install an essential clutch and heavy-duty clutch, including a special clutch.

Essential clutch

Models12V Monkey and Gorilla
Benly CD50/CL50/50S
12V DAX
XR50R/CRF50F
Super cub 50
Little cub

PYPart No.
02-01-0202（No change in primary reduction gear ratio）
02-01-0214（Primary reduction gear ratio to 18/67 from 16/69）
02-01-0215 Heavy-duty Centrifugal Clutch Kit
02-01-0511 Kit to change centrifugal clutch to the manual clutch
Kit to change centrifugal clutch to the manual clutch
02-01-0512(with clutch and lever only for XR50R / CRF50F)
02-01-0215

Heavy-duty Centrifugal Clutch Kit

3 Change of sprocket◇ The installation of this kit will increase the power of your vehicle. So with the stock sprocket, you will find it uncomfortable todrive your bike because the gear ratio is too low, and will cause severe wears of hardware, not only adversely affecting the engine
life, but also possibly breaking the engine in the worst case. Therefore, please replace the drive and driven sprockets to make thegear ratio higher.
※ Please note that a driven sprocket is not included in the kit.
※ Furthermore, the gear ratio of the sprocket changes according to the clutch type and wheel size. The list below is just for yourreference because the configuration in the list below needs to be changed according to the driver’s weight and purpose of use.
※ When changing the driven sprocket, remove hardware around the rear wheel. Raise the rear wheel off the ground by placing amaintenance stand under the engine for working safely.

Recommended sprocket for use with S-Stage, SCUT (with a driver weighing 65 kg)
ModelsBenly CD50/CL50/50S
12V DAX

17 inch
10 inchSpecifications
ClutchManualHeavy-duty special
ManualHeavy-duty special
ManualCentrifugal

Super cub 50

17 inchCentrifugal

Little cub

14 inchCentrifugal

12V Monkey and Gorilla

Rear wheel size
8 inch10 inchTransmission
4-speed
4-speed
4-speed
4-speed
4-speed
3-speed
4-speed
3-speed
4-speed
3-speedRecommended Sprocket
Drive sprocket (Front)
Driven sprocket (Rear)
16
23
16
25
16
25
16
28
16
42、43（Stock）
16
31
16
42
16
35
16
41（Stock）
16
35◇ When the stock sprocket is changed to the recommended driven sprocket, the drive chain becomes too slack or too short. However,
it is impossible to take up the slack of the drive chain just by adjusting the free play. You need to either shorten the chain by
cutting it with a chain cutter, or to prepare a new drive chain. Especially, in the case of the Monkey, the length of chain changes
according to the length of swing arm.
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■ Mounting procedure※ Please refer to the Genuine Service Manual for detailed mounting methods and specified torques that are notspecifically described.

● For best performance
1 Carburetor
Higher power can be attained through the installation of Big Bore Carburetor Kit suitable for each model of a bike for the best
performance of S-Stage.

Recommended Big Bore Carburetor Kit for S-Stage, SCUT
Models12V Monkey and Gorilla
Benly CD50/CL50/50S
12V DAX
XR50R/CRF50F
Super cub 50
Little cubPart No.
03-05-320 (PC18)
03-05-0045 (VM22)03-05-033 (PC20)
03-05-321 (PC18)
03-05-0047 (VM22)03-05-3244 (PC18)CO
03-05-039

2 Muffler

Please install our various kinds of exhaust system for higher power output.

3 Oil cooler

As a longtime high-load driving will further increase the heat release value of the engine, we recommend you to install an Oil Cooler
Kit which keeps oil at appropriate temperatures and prevents such troubles as oil film shortage at high temperatures.

○ For details, please refer to our parts catalog or website.
http://www.takegawa.co.jp

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