Hyper S-Stage V-KIT C Type Instruction ManualThis is a newly introduced kit which can bore up to 88cc with a stock 50cc cylinder head, on which you canenjoy the feeling of a real powerful engine. This kit is designed for you to install as easily as you assemble aplastic model and have a good time studying the engine structure, as if you enjoy street fashion.

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Item NO ：０１−０５−０２３６
Model：Monkey / Gorilla / BAJA
Frame NO ：Z50J-2000001 〜：AB27-1000001 〜・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 yourdealer.
◎ Please note that, in some cases, the illustrations and photos may vary from the actual hardware.

Cautions about fuel to use

This S Stage Kit product is so designed to achieve a higher compression ratio than stock engines. As for the fuel, therefore, 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 malfunction. 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 it with highoctane gasoline.

Cautions 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.

The cautions about a sprocket

The installation of this product will increase the power of your vehicle. So use of a stock sprocket will result in severe wears of parts
because of the too low gear, not only adversely affecting the engine life, but also breaking the engine in the worst case. With a 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.

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Please be sure to read the following before use◎ 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.
◎ 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, 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 product cannot
be mounted on other types of motorcycles.
◎Before installation, prepare the tools 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 is advisablethat those who do not have such tools, or skills or knowledge contact a technically reliable specialist shop for installation.
◎ The cylinder and cylinder head gasket in this kit 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.
◎ 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 kit's 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, as well as air cleaner elements. If you exchange the carburetor, please have a set
according to the model. Disregarding of 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 and damages to human bodies as a result of conduct

CAUTION 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.)・Set torque at a specified level with a torque wrench. Otherwise, improper torque will 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.)・Please replace gaskets and packngs with new ones. As to the parts for reuse, check carefully for wear and/or damage. Always replace worn or
damaged ones with new ones.
The following show the envisioned possibility of the injuries to human bodies or physical damages as a result of

WARNING disregarding the following cautions.

・Please try to ride a motorcycle at legal speed on the public road, abiding by the law.
・Work only when the engine and the muffler are cool. (Otherwise, you will burn yourself.)
・Prepare tools suitable for the work. Otherwise, the parts will be damaged or you will suffer injuries.
・Set torque at a specified level with a torque wrench. Otherwise, improper torque will 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.)
・EBefore 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.
・Exchange the gaskets and packings with new ones. And as for those parts to be reused, check them for wear or damages.In case wear or damage is
detected, always replace them with new ones
‑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◇ Usually, bolts and nuts are loosened by counterclockwise turns, and tightened by clock wise turns.
◇When tightening a screw, at first tighten it by hand as tight as you can. If you cannot get it moving more than one or two turns, check if the screw is placedat an angle.
◇ To loosen a screw means turning a tightened screw around three or four times counterclockwise, and to unscrew it means turning it aroundcounterclockwise until it comes off.
◇ To tighten a screw means to keep a screw from getting loose. The numeric value as a guide at which a screw will not break or get loose when tightenedis the so-called "tightening torque." If you do not have a torque wrench, please try to tighten a screw as tight as possible to the level where the screw willCO

not break or get loose, though we can not take any responsibility for the breakage. In case we do not use a torque wrench, we need to judge, only byintuition 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.

◇Kit’s Contents

０１―０２―５１７
Piston kit

１

５

３

２

４

９

１１

１３

１２

１４

１０

１８

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２１

１９

NO
1
2
3
4
5
6
7
8
9
10
11
12
13

Parts Name
PistonPiston ring
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)

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

８

１７

１６

１５

２３

２２
２０

７

６

２４

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

NO
14
15
16
17
18
19
20
21
22
23
24
25

Parts Name
Camshaft
DENI18 Carburetor assembly
Inlet pipe
Air filter (with a band)
Carburetor gasket
Inlet pipe gasket
Socket cap screw, 6X20
Socket cap screw, 6X25
Throttle cable, 710mm
Spark plug CR8HSA
Drive sprocket（with a plate）16T
Main jet #85

Qty
１
１
１
１
１
１
２
２
１
１
１
１

２５

Repair Part Item No.
01-08-0009
03-03-0061
17111-GBO-T00
03-01-110
16201-GEY-T01
91301-181-T01
00-00-0043
00-00-0089
09-02-0071
02-05-051
00-03-0041

in packs of
1
1
1
1
1
1
10
10
1
1
1

※ Please order repair parts with the Repair Part Item No. Without the repair part item No., we may not be able to provide the correct parts.
Some parts are only available as a set. Please order them with the set number.
‑2‑

Dec./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

CylinderLeft-side cylinder head side coverLeft-side cylinder headside cover gasket※3 Be sure to change to CR8HSA (NGK) or
U23FSR-C (DENSO).

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

※1 Dowel pin, 8x12
Dowel bolt, 5 MM

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

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

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

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Dec./17/ 12

Stock Parts Removal

2． Fuel Tank Removal

1．Seat Removal

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Clump
◇Take out the hose of the strage tank (only in case of no.
AB27-).

◇Turn the fuel cock off.

Wire harness◇Shift the wire harness to underneath the frame.

4．Muffler Removal◇Remove the side cover.

◇Remove the bolt of the air cleaner stay.
Tools:
10 mm box wrench◇Rotate two nuts on the EX pipe counterclockwise andremove them.
Tool:
10 mm open-end wrench

Extension bar (small)

PY◇Shift the tube clip upward and disconnect the
carburetor’s fuel tube.

◇Loosen the nuts under the seat, and unscrew thebolts.
Tools :
12 mm box wrench
Extension bar (small)
10 mm offset box wrench◇Remove the hex bolt which is used to fix the muffler
by turning it counterclockwise.

Tools:
12 mm box wrench
Extension bar (medium)◇Remove the bolts which mount the fuel tank on the frame.
Tool:
10 mm offset box wrennch◇Remove the nut on the back of the muffler by rotating
it counterclockwise.

◇Unscrew two bolts which are fastening the inlet pipe
and the cylinder head together. Then remove the inlet

Tools:

10 mm box wrench
Extension bar (medium)

pipe, the carburetor, and the air cleaner.

Tool:

8 mm offset box wrench◇Remove the fuel tank by pulling it backward.
◇Remove the two flange collars, and take the muffler
off the body as if by pulling the muffler outward.
◇Loosen two nuts on the rear shock.
Tool:

3．Carburetor Removal

14 mm offset box wrench◇Install the earth wire to the frame by air clearner stay’s
bolt.
Tools:
10 mm box wrench
Extention bar (small)
Torque 12N・m (1.2kgf・m)◇Detach the carburator’s top cap and take out the throttle◇Remove the seat by pullying it backward.

valve from the carburetor.

‑4‑

Dec./17/ 12

5．Front Fender Removal

CO◇Remove the head cover. (If it does not come off easily,
strike it lightly with a plastic hammer,and it will comeoff.)

◇Rotate the two hex bolts on the back of the front fendercounterclockwise and remove them.
Tools:

10 mm box wrench
Extension bar (small)◇Rotate the three bolts which are fixing the crankcase L◇Prise the cam sprocket open with a small flat tip

cover counterclockwise and remove them.
Tools:
8 mm open end wrenchscrewdriver or something like this to remove it from thecam shaft.

them off completely with a scraper or a cutter.

◇Remove the cam chain from the cam sprocket first, andthen remove the cam sprocket.

8 mm box wrench

6．Spark Plug Removal◇If some gaskets remain on the cylinder head, wipe

◇Remove the dowel pin fixed in the center of thecamshaft.

Extention bar (small)

13．Cylinder Head Removal◇ Let the front tire down. (Push the valve with the tip ofa cross slot screwdriver or something like this, then

9．Two Tappet Caps Removal

the tire will deflate.Push it till the whoosh cannot be

11．Cylinder Head Side Bolt
Removalheard any longer.)◇Remove the plug cap from the plug by pulling it out
from the plug. Be sure to hold the cap when pulling
it out.

◇Remove the plug by turning it counterclockwise with
the in-vehicle spark plug wrench.

7．Cylinder Head Left Side
Cover Removal

PY◇Pull the cylinder head away from the cylinder toremove it. (If the cylinder head does not come out◇Rotate the two tappet caps counterclockwise, andremove them.
Tool:

17 mm offset box wrench

which are used to fix the cylinder head and the cylinder,and remove the bolt.

Tool:
10 mm open-end wrench

10．Cam Sprocket Removal
Notchsmoothly, strike it lightly with a plastic hammer.)◇Rotate counterclockwise the cylinder head side bolt

Guide roller bolt

◇Remove the cylinder head while pushing the front◇Unscrew the hex bolt in the center of the cylinder
head right cover, and the left cover comes off.
(If you cannot remove the left cover in this way, screw

Side bolt◇Keep the two dowel pins for reuse.

Engraved “O” markin the hex bolt a few screw threads and strike the topof the hex bolt with a hammer lightly.)
Tool:

tire. It seems that at this point, you come tounderstand why you have let the front tire down.

◇Loosen the cylinder’s guide roller bolt and the side bolt
between the cylinder and the crank case by rotating
them.

Notch

10 mm box wrench

14．Cylinder Removal◇Loosen the cylinder’s guide roller bolt and the side bolt
between the cylinder and the crankcase by rotatingthem.

12．Cylinder Head Cover Removal

Flywheel◇Rotate the flywheel counterclockwisen, aligning the◇Rotate counterclockwise the guide roller bolt andthe cylinder side bolt which were loosened, and“T” mark on the flywheel and the “O” mark on the cam
sprocket with each notch.

remove them.

8．Crankcase Left Side Cover
Removal◇Rotate counterclockwise four nuts which are mounting
the cylinder head cover in a diagonal order, and removethem.
◇Remove four washers under the nuts.
Tool:
10 mm box wrench

10 mm offset box wrenchsmoothly, strike the cylinder lightly with a plastic
hammer.)◇Fix the flywheel, turn two camsprocket hex bolts◇Unscrew the hex bolt on the shift pedal, and turn theshift pedal counterclockwise and remove it.
Tool:◇Pull and remove the cylinder. (If it does not come out

counterclockwise, and remove them.
Tools:
8 mm box wrench
14 mm offset box wrench (For fixing a flywheel)‑5‑

Dec./17/ 12

◇Arrange the ring-end gaps of piston rings to meet

16.Removal of a Cylinder Base Gasket,

each other.

an O-ring, and a Dowel Pin
Cylinder base gasket

Top ring
120°

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120°

120°

◇Remove the cam chain guide which will come out
when you pull out the cylinder.

Second ring
ExpanderO ringSide rail

60° 60°◇After the piston has been taken out, remove thecylinder out forward while holding the tire by hand.

15．Piston Removal“R” is engraved on the uppersurface of the top ring, and“RN” on the second ring top◇In case you cannot remove all the gaskets completely,rasp or wipe them off with a scraper or something else,
exercising great caution not to scratch the crankcase.
If the crankcase center gaskets protrude into thecylinder base or the cylinder hole, cut them off.

S - Stage Kit
Installation

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Be careful not to let any foreign matter fall into the
crankcase.

◇Cover the cylinder hole and the cam chain in the

crankcase with a waste cloth so even a single
foreign matter like a part and the dust will never fall
down into them.

surface.
Top ring
Second ring

1．Piston Installation

Side ring

Pistonピスト
ン
ExpanderTake note of cross section◇If the gaskets run off at the point indicated with a finger
in the above picture, cut them off.

◇Fit a piston pin circlip, attached to one side of thepiston, firmly in the circlip groove. In so doing, see to it

Cautions about Alminum
Cylinder Installation
Piston pin circlip◇Remove one of the two piston pin circlips.
◇You can remove it by prising it open with ascrewdriver with its tip on the notch.
Tool:
A tapered flat tip screwdriver◇Remove the piston pin in the direction where a piston
circlip has already been removed. You can easily
remove it by pushing it up with a flat tip driver from thedirection where another piston circlip remains fixed.

◇Remove the piston.

that the circlip’s end gaps do not meet with the notchon the pin hole.

In some cases, due to right and left
crankcases being out of alignment andfor other reasons,in installing thecyliner, there may be interferance insleeve hole of the crankcase’s mating
surface, circled parts, shaded areasof the cylinder sleeve, and inside thecase. Since such intereferance will leadto sleeve deformation and engine
troubles, do not fail to check and perform maintenance.
The difficulty level of the work is quite
high. So, you may feel like being a professional if you have successfullycompleted the job.

How to Modify
1．Cover the crankcase securely witha waste cloth so the shavings will
not fall down into it.
2．Rasp the convex portions on themating surfaces of the crankcase
till the surfaces become level.
3．Then, remove the waste cloth withcare not to let the shavings go
inside the crank case.
4．After taken off the waste cloth,thenstuff a clean waste cloth into thecase’s hole.
5．After assembly of the kit iscompleted, leave the engine idlingfor several minutes. Right after this,exchange the engine oil for newone. Then everything is set.

Left
side

◇Fix the oil ring expander.

◇You can relatively easily install it by pressing it with ascrewdriver. But take care not to damage the piston witha screwdriver.
◇A left side piston pin circlip should be installed first.
Tool:
A tapered flat tip screwdriver◇Apply engine oil to the ring grooves and install the‑6‑piston rings in the following order; an oil ring expander,
an under oil ring side rail, an upper oil ring side rail,
second ring, and a top ring.

◇Fix the lower oil ringside rail.

◇Fix the upper oil ringside rail.
Dec./17/ 12

CO◇Fix the second ring.

◇You can rather easily install it by pressing it into thepiston with a screwdriver, but taking care not to damage
the piston with a screwdriver. Do the job carefully as, in◇Insert the cylinder while holding the tire.

◇Fix the guide roller bolt. (Temporarily tighten it astight as possible by hand. )some cases, the circlip comes off flying while you press
it inside. So, wear protective eyeglasses for your eye
protection.

◇Take away the waste cloth.

2．Cylinder Installation◇Degrease the cylinder and crankcase sides of the◇Fix the top ring.

cylinder base gasket surface with thinner or the like.
◇Press the cylinder little by little with fingers, with care ◇Install the cylinder side bolt. (Temporarily tighten it
not to move the piston rings’ end gaps.
as tight as possible by hand.)The degree of difficulty is very high. Do your best!

3．Camshaft Replacement

PY◇Once the rings are set in the cylinder, letting the cam
chain go through the cylinder, fit it into the crankcase.

◇Remove the tappet nut and bolt on the rocker arm◇Apply engine oil to the piston pin and the connecting
rod, and install the piston pin.

◇Fix the cylinder base gasket and a black rubberpacking.

which are installed in the cylinder head. At the time
you have loosened the tappet nut, remove both thetappet nut and bolt at the same time.
Tool:
9 mm offset box wrench◇Install the guide roller while pulling the cam chain.

Exhaust side
◇Install the piston with the arrow on its top surface
facing down, or facing toward the exhaust side.

◇Check that the two dowel pins are installed.

◇Install the cam sprocket bolt to the camshaft, and takeout the camshaft by rotating it. Never try to pull it out
forcibly.
◇Apply engine oil to the inside of the kit’s cylinder,and◇It makes the installation easier to insert the wrist pin
spread it with fingers to be equally applied.
one third at first.
◇Fit the kit’s piston pin circlip to the circlip grooves
exactly.
◇Push the guide roller deeper inside till the guide roller
center meets the hole of the guide roller.

‑7‑

Dec./17/ 12

5．Cam Sprocket Installation
Notch

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◇Install the kit’s camshaft in the order reverse to
installing it.

Apply clean engine oil to the cam profile and thejournal of the cam shaft. Even if it is difficult to fit the

Hex nut◇Pass the cylinder head through the stud bolt while
pushing the tire by hand.

◇Align the “T” mark on the flywheel with the notch on◇Passing the cam chain through the cylinder head,the crankcase.

install it.

cam shaft, never strike it with a hammer, etc. Justpress it by hand.

◇Screw the head nuts equally tight. (If without a torquewrench, tighten them firmly little by little diagonally.)
Torque 12N・m (1.2kgf・m)◇Attach the dowel pin of a stock cam in a kit cam.

◇Fix the cam chain by putting a screwdriver in thecentral hole on the camshaft.

◇Fix the rocker arm’s tappet screw by turning it
clockwise.

Tool:
10 mm box wrench◇Set one of the cam shaft’s holes at the position to bein parallel with the notch on the cylinder head; This
arrangement places the cam shaft at TDC (Top Dead
Center) on the compression stroke.

PY※In the case of optional cam shaft installation, follow
the instructions in its own instruction manual.

◇Install the cylinder head cover’s gasket and the head
cover.

4．Cylinder Head Installation◇Degrease the head surface and the upper surface ofthe cylinder with thinner, etc.

◇Install the head side bolt. Tighten fully the guide rollerbolt and the cylinder side bolt which were temporarily

Wipe off steeping oil aftertightened beforehand.

tightening.

Tool:

10 mm open-end wrench
10 mm offset box wrench

Pay attention to the arrow.
◇Take note that the arrow faces downward.

◇Install two dowel pins to the cylinder.

The job is very difficult, so do your best!
◇Remove a hex’ bolt beside the change pedal shaft,so the tention of the cam chain will be loosened andit becomes easier to install the cam sprocket.
Reinstall the bolt after installing the cam sprocket.
Appling the cam chain to the cam sprocket, install the
cam chain to the cam shaft so the “O” mark on the
cam sprocket and the notch on the cylinder head
are aligned with.

◇Install the head gasket.
※The rubber packing (black) and the rubber gasket(green) are not used here.

Copper washer◇Install the head cover’s washers and nuts. Above is the
picture of an engine seen from the front. At the lower left
are a copper washer and three iron washers, and at thelower left is a hex nut and the remaining three are cap
nuts.

‑8‑

Torque:Guide roller bolt 10N・m (1.0 kgf・m)
Side bolts, upper and lower 10N・m (1.0 kgf・m)

Dec./17/ 12

7．Cylinder Head Left CoverInstallation

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9．Stock Muffler Installation◇Fix the flywheel and tighten two cam sprocket bolts.
◇While tightening a rocker arm’s tappet screw, tighten◇As to the muffler installation, pass the tail pipe through
Torque 9N・m (0.9kgf・m)
the tappet nut to the extent that a 0.05 mm thicknet gauge,
the rear shock first and have the flange part near the
Tools:
placed between the tappet screw and the valve stem
exhaust output.
8 mm box wrench
end, can be pulled out with only a little resistance. If you ◇Fix the cylinder head left cover gasket and the left cover.
14 mm offset box wrench(Set the stopper at the position indicated in the picture
have no idea of the proper resistance in pulling out thein order for the Lside cover not to turn clockwise when
0.05 mm thickness gauge, then prepare a 0.07 mm andtighteing the bolts.)
6．Valve Timing and Tappet
0.03 mm thickness gauges.The 0.05 mm space is when

Adjustment

the 0.07 mm gauge won’t go in between the space but

Very difficult work, and do your best here!

the 0.03 mm gauge goes in with little resistance. Set
the clearance at 0.05 mm both for intake and exhaust.
Tools:
Needle nose plier

Notch

9mm offset box wrench
Thickness gauge

Engraved “O”

Cylinder head side

Notch

◇Install two flange collars as if to squeeze theexhaust pipe.

PY(Set the stopper as shown in the
picture above.)◇After adjusting the tappet, turn the flywheel
counterclockwise twice by hand, and then, align the “T”
mark with the “O” mark.

◇Tighten two nuts on the exhaust pipe(temporary
tightening).
Torque 10N・m (1.0kgf・m)
Tool:

Flywheel side
◇Turn the flywheel until the “O” mark on the cam shaft
and the “T” mark on the flywheel meet each notch.
Though the flywheel will not stop right at the required
postion because the magnet repels each other, it’s

10mm open-end wrench

all right if “T” and “O” marks meet each notch at the◇Check for tappet clearance change. If changed, adjust
same time after fixing the cam sprocket.
the clearance again.

Valve clearance(Intake side)◇Tighten the hex bolt (see arrow) on the cylinder head ◇Install nuts to the back side of the muffler (temporary
right side.
tightening).
Torque 12N・m (1.2kgf・m)
Torque 10N・m (1.0kgf・m)
Tool:
10mm box wrench

Tools:
10mm box wrench
Extension bar (Medium)8．Spark Plug Installation

Valve clearance(Exhaust side)
Adjustment screw◇Install and tighten the hex bolt which mounts the muffler

Thickness gauge
Valve stem

◇Fix two tappet caps.
Torque 12N・m (1.2kgf・m)
Tool:◇Install the plug with in-vehicle tools or a spark plug
wrench.
Torque 11N・m (1.1kgf・m)
Tool:
Spark plug wrench

17mm offset box wrench(temporary tightening).
Torque 26N・m (2.7kgf・m)
Tools:
12mm box wrench
Extension bar (Medium)◇Tighten fully three sections tightened temporarily
beforehand.

◇Install a plug cap on the plug.

‑9‑

Dec./17/ 12

10．Front Fender Installation

CO◇Detach the top cap from the carburetor, and take out
the spring and the throttle valve.
◇Fix kit’s main jet.

◇Connect the inner cable with the throttle pipe.

Tool:◇Tighten and fix the hex bolt at the back of the front

Flat tip driver (Medium)fender.

Torque 10N・m (1.0kgf・m)
Tools:

10mm box wrench

Extension bar (Small)◇Blow up the tire.

11．Throttle Cable Installation◇Unfasten the wiring of the stock throttle cable.

◇Fix the upper throttle housing with two screws.
※In this case, tighten the front screw first, and then theone on the back side.

Align like this.

◇Fix the float chamber to the carburetor with two screws.

◇Loosen the hex nut.
Tool:

14mm open-end wrench

PY
13．Carburetor Installation

Inlet pipe gasket※In the case of a stock handle, set the crank in the throttle
housing at the “O” mark on the handle. (See the picture
above.)◇Wire the throttle cable.

12．Main Jet Replacement◇Fix the top cap onto the throttle cable, and fix the

Float Chamber◇Put the inlet pipe gasket between the intake manifold
and the cylinder head, and fix the gasket by tightening◇Unscrew two screws and detach the upper throttle
housing.

spring and the throttle valve onto the inner cable.

Notch

two 6x25 socket cap screws.

Torque 12N・m (1.2kgf・m)

Tool:
5mm hex wrench

ScrewsCarburetor
gasket◇Align the notch on the throttle valve with the throttle◇Unscrew two screws and take off the float chamber.
Tool:
Cross slot screwdriver (Medium)

Throttle
stop
screw

stop screw, and insert the throttle valve into the
carburetor.

Float pin

◇Detach the throttle cable’s inner cable from thethrottle pipe.

◇Put the carburetor gasket between the intake
manifold and the carburetor, and fix the gasket bytightening two 6x20 socket cap screws.
Torque 12N・m (1.2kgf・m)
Tool:
5mm hex wrench◇Fit the top cap into the carburetor as shown in the
picture above.

※Take note that the float pin often comes off easily.

◇Detach the stock throttle cable from the lower throttle
housing.

Jet holder

14．Adjustment of Play in theThrottle
Main jet◇Detach the main jet from the jet holder.
Tool:◇Fix kit’s throttle cable to the lower throttle housing.

◇Pull down the boots on the throttle cable to expose
the adjuster.

Flat tip driver (Medium)‑10‑

Dec./17/ 12

16．Fuel Tank Installation

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Master link

Link plate◇Holding the hex nut, loosen the adjuster.
Tool:
8mm open-end wrench
10mm open-end wrench◇Insert the bolt into the lower part of the seat and fix the ◇Remove the link plate and the master link first, andthen remove the drive chain.
nut.
※Do not fail to stop the engine before setting to work.
Torque 22N・m (2.2kgf・m)◇Install the fuel tank to the frame.

Tools:

Throttle cable

12mm box wrench
Extension bar (Small)
12mm offset box wrench

遊びが多く
なる
More
play

adjuster
アジャ
スター

六角ナッ
ト
Hex’ nut

Less play◇By turning the adjuster, you can adjust the degree offree play.

about 5mm

◇Fix the fuel tank to the frame with a bolt.

10mm offset box wrench◇Fix the adjuster and tighten the hex nut.
Tools:
8mm open-end wrench

PY◇Connect the fuel tube with the carburetor.

◇By turning the throttle, check that the throttle valve

Extension bar (Small)◇Remove the plate.

◇Tighten two nuts on the rear shock absorber.

moves smoothly and without a hitch.

Torque 34N・m (3.5kgf・m)◇Check that there is free play in the throttle even when
you turn the handle all the way to the right and left.
◇Replace the boots in the original position.

Tools:
10mm box wrenchTool:◇Adjust the throttle grip to have about 5mm free play.

10mm open-end wrench◇Remove two bolts, applying the rear brake.

Torque 12N・m (1.2kgf・m)

17．Seat Installation

15．Air Filter Installation

Tool:
14mm offset box wrench◇Take the stock sprocket out of the shaft, and remove
the chain.

◇Install the side cover.

◇Attach the band to the airfilter and insert it into the
carburetor. Tighten the band.

18．Drive (engine side) Sprocket
Installation◇Insert kit’s sprocket into the shaft.

◇Fix the hook of the seat tray by inserting it between two
washers of rear shock.

◇Install strage tank’s hose to the air filter.
(in the case of vehicles of frame No.AB27)

Clip◇Remove the clip on the drive chain.

‑11‑◇Install kit’s plate and temporarily tighten two bolts.

Dec./17/ 12

19．About Driven Sprocket (rear-tire side)※ With the change of the driven sprocket, the driven sprocket has to be changed as well, and the sprocket needs to be in high gear.
※Driven sprocked must be determined according to types of a clutch and size of tire. Refer to the following list for the details.
★Recommended Sprocket for Hyper S-Stage Kit CType (for 65kg weight)
Tire size

DrivesprocketClutchDrivensprocket

Ratio

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8
inc
10
inc

Stock manual

16

23

1.43

Strengthening, special

16

25

1.56

Stock manual

16

25

1.56

Strengthening, special

16

28

1.75

◇Carry out this bundle of the bolt of the drive sprocket which temporary-stopped and was
being carried out.

※Driven sprocket is not included in this kit. Please purchase it (or them) separately.

Torque 12N・m (1.2kgf・m)※Before replacement of driven sprocket, you have to remove all belongings of the rear wheel.

Tool
10mm box wrenchStand the vehicle firmly by a racing stand or the like, and suspend the rear wheel.

Extention bar S

20．About Drive Chain

21．Crankcase Left Cover Installation※In some cases, replacement of the stock sprocket with the recommended one will make the drive chain too short even iif the chain
is adjusted. In such a case, prepare a drive chain separately and adjust the length. In addition, length of the chain varies according
to the length of a swing arm. Refer to the following list for the detail.

★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

DrivenSprocket

Stock swing arm

4 cm Stretch

8 cm Stretch

12 cm Stretch13(Stock)31(Stock)74(Stock)

−

−

−

−

16

23

72

76

84

90

98

16

25

72

76

84

16

28

−

−

−

Drive chain

１

２
Removehereトします
ここでカッ

16 cm Stretch

PY
90

98

92

100

◇Install and tighten three bolts which are fixing the crankcase L cover.
Torque 10N・m (1.0kgf・m)
Tools:

8 mm box wrench

Extention bar (small)◇If you need to replace stock sprockets (stock swing arm) with a drive sprocket 16 T / a driven sprocket 23T, remove two links from thestock chain.
※Always stop the engine in this procedure.

◇Fix the drive chain to the drive and driven sprockets.

◇Fix the change pedal.

Master link

Torque 10N・m (1.0kgf・m)
Tool:
10mm offset boc wrench◇Check for slackness of the bolts fixed all the way from the engine to the suspension.

Link plate◇Reinstall the master link from inside to connect the drive chain, and then reinstall the link plate also.

◇Turn on the fuel cock.

Clip

Direction of
travel◇Fix the clip.
※At this point, clip’s end gap must face toward the reverse direction of travel.

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./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