Z-Style Exhaust system (TYPE-2) Instruction Manual
Product number 04-02-2308

Adaptation model

Monkey・Gorilla(Z50J-1300017 ～ )(AB27-1000001 ～ 1899999)

Thank you for purchasing one of our products. Please strictly follow the instructions to install and use the kit.
Before installing the kit, please be sure to check the kit contents. If you have any questions about the kit, please contact your local
TAKEGAWA dealer.
Before installation, please read this instruction manual carefully and understand the instructions fully.
Enjoy the sound and performance of this exhaust system distinct from a stock exhaust system.
◎ Please note: Illustrations and photos may vary from actual hardware.

CO☆ Please read carefully before use ☆

◎ The following show the envisioned possibility of injuries and damages to human bodies, and physical loss or damage as a result ofdisregarding the following cautions.
◎ We shall be held free from any kind of warranty whatsoever of products other than this product if the any defect takes place on theother products than this one after the installation and use of this product.
◎ 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.
◎ Please refrain from combined use of this kit with any other part than the specified parts.
◎ Though a genuine exhaust system guard can be fixed as it is, processing is necessary as the guard-mounting portion is partiallyexposed.
◎ Product may have edges or protrusions. Be sure to wear working gloves.
(Please wear work gloves when working, even if a photo in this article show without work gloves.)◎ This product is designed for exclusive use with a stock kick starter arm. (In case of our kick starter, the arm will interfere withthe genuine exhaust system guard.)◎ Cannot be installed old type dry clutch kit (wire type)
Note: Can install our special clutch TYPE-R (WET/DRY) (wire type/hydraulic type) and 5 disc special clutch at the same time.
◎ Applicable rear shock is“stock”or our rear shock with chrome body. Other rear shocks may interfere the exhaust system.
NOTE: KYB MG/MGS, our rear shock with a cover and other manufacturer’s rear shocks may interfere depending on the mounting positionor angles of canister’s end pipe or rear shock absorber. Be sure to check the size by yourself before installation.
◎ Cannot be used with our bore stroke up 138cc.
◎ leakage can be reduced by using a gasket agent for the connecting part.(but not eliminated completely.)
Please apply the recommended heat-resistant gasket agent when installing.
In addition, the heat-resistant gasket agent will deteriorate with use, so please perform maintenance frequently.

～ Features ～PY○ This is a genuine-like up-exhaust system for the Monkey, to which a genuine exhaust system guard can be installed.
It improves the performance without altering the original look of the Monkey.
○ We have adopted a canister body and exhaust pipe, both made of stainless, to improve the appearance and durability.
○ This canister has a straight internal design, which features moderate sound volume and wide variety of use.

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 the 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.
■ The product and the frame, might have edges or protrusions. When working, please wear work gloves to protect your hands.
（It may cause injury.）■ Do water washing of an exhaust system only when it is cool. (Otherwise, the exhaust system may be cracked.)■ Park your motorcycle in a place where pedestrians will not touch the exhaust system accidentally. Besides, please always be considerateenough not to park it in the way of pedestrians or moving vehicles.
(If you park your motorcycle on the sidewalk with its exhaust system on the pedestrians’side, the pedestrians may touch the exhaustsystem and get burned or suffer property loss.)■ 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.
■ This exhaust system is designed for exclusive use with a stock kick starter arm. TAKEGAWA’s kick starter arm will interfere with thegenuine exhaust system guard.
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)2024.1.19

04-02-2308

/4

Warning

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

■ 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.)■ Never look into the outlet of exhaust system when the engine is revolving.
(Otherwise, you will suffer from carbon monoxide poisoning or lose your sight.)■ When you notice something abnormal with your motorcycle, stop riding immediately and park your motorcycle in a safe place to avoid
an accident.
■ Before riding, be sure to always check the bank angle, and run with care not to bank the vehicle more steeply than the bank angle.
(Otherwise, there will be a danger of the motorcycle overturning.)■ The engine and the exhaust system are at high temperatures when the engine is revolving or for some time after the engine stopped.
Therefore,never place flammable or hazardous materials such as gasoline near them.
(Otherwise, there will be a danger of causing fires.)■ Before working, place the motorcycle on level ground to stabilize its position for safety to avoid the motorcycle overturning.
■ Check or perform maintenance of parts correctly according to the procedures in the instruction manual or a service manual.
(Improper checking or maintenance could lead to an accident.)■ 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.)■ Keep plastic bags for packing products out of children’s reach, or discard them.
(If children get them on, there will be a danger of their suffocating. )■ Basically, you can install this exhaust system in almost the same way as installing a stock exhaust system. Although a genuine
exhaust system can be fixed, a guard for an exhaust pipe (right behind the engine exhaust) cannot be installed. So, please do be
careful not to let your right leg touch the exhaust pipe when pressing down on the rear brake pedal.
Besides, do not ride the vehicle in an exposed style, such as in sandals. (It could lead to burn or accidents.)

CO◎ 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.
◎ Please be informed that we shall be held harmless against any claim against us whatsoever arising out of use of the products inracing and the like.
◎ We do not have any information or service data on the combination of our products and other manufacturer’s products.
◎ You are requested to keep this instruction manual until you discard this product.

PY

Product content①③④⑤

Number12
3
45
6

Product content
Canister assembly
Pipe COMP.
Exhaust pipe flangeCollarFlange bolt, 8x30
Exhaust pipe gasket②⑥Quantity
11
1
1
1
1

Item Number

00-04-012100-00-2335
00-00-0181 (4 pcs)
00-01-0064 (2 pcs)

※ Please order in the repair parts are always repair part number.
If it is not the part number order, you may not be able to order.
Please be forewarned.
It should be noted, In the case of parts that can not be separately shipment,
please order a set part number.
※ Repair parts may differ slightly from the kit contents in terms of shape, etc.
There is no problem to use it. Please be forewarned.
2024.1.1904-02-2308

/4

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

Stabilize the vehicle with a maintenance stand or the like in a safe and level place during work.
● Genuine Exhaust System Removal○ Unscrew the bolts on the air cleaner stay.
CAUTION : Work only when the engine andthe exhaust system are cool.

● Genuine Exhaust System Guard Removal○ After removing two collars on the exhaust
flange,remove the exhaust system from thebody by pulling it outward.

CO※ CAUTION: Plus screws may be very tightly
screwed, so unscrew them withenough care not to damage theirheads.

○ Though the genuine exhaust system guard
can be installed as it is, the bracket,
which is fixing the guard on the exhaustpipe, gets exposed without processing.
Therefore, cut off the unnecessary part.

○ Loosen the band which is clamping thecarburetor and the air cleaner, andremove the air cleaner.

○ Unfasten the nut on the back side of theexhaust system.

※ CAUTION: Once the bracket is processed or
cut off, the guard on the exhaust
pipe of the normal exhaust system
will be rendered not installable
any more.

PY

Cut off this part

○ Remove the old exhaust pipe gasket
remaining in the exhaust port.

○ Unfasten two nuts on the exhaust pipe flange.
Keep them for re-use.
If the nuts are worn or damaged severely,
replace them with new ones.

○ Reinstall the removed air cleaner in theorder opposite to its removal.
※ On to a 12V motorcycle, never forgetinstalling earth wires.

○ Unfasten the hex’bolt which is fixing
the exhaust system.

2024.1.19

Note: Be sure that you protect specified
torque.

Torque：8 ～ 10N・m（0.8 ～ 1.0kgf・m）

04-02-2308○ Remove the exhaust system guard from thejust-removed genuine exhaust system.
○ Unscrew all plus screws which are fixing
the exhaust system guard to the exhaustsystem. Keep those screws for re-use.
If the screws are worn or damaged severely,replace them with new ones.

/4○ If the exposing portion is cut off, it
is advisable to give a touch-up to thecut surface with a heat-resistant paintto prevent the surface from rusting.

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

● Z-Style Exhaust System Installation○ Insert and install a kit’s exhaust pipe
gasket to the exhaust port.

● Final Checking○ Check the clearance between the exhaust
pipe of canister and the rear fender, andthen adjust the positions of the canisterand the exhaust pipe so that they do notinterfere with each other.

○ Start the engine in a safe andwell-ventilated place, and check for
exhaust leak or interference.
WARNING: Be sure be preformed in awell-ventilated place.

○ After stopping the engine and after eachpart has cooled down to the normal
temperatures,re-tighten all screws andnuts to the specified torque.
Note: Always be performed cold state.
Note: Be sure that you protect specifiedtorque.

Exhaust pipe gasket

CO○ Temporarily install the canister assemblyto the vehicle in the following order.
First, pass the rear end of the canister
pipe from behind the upper part of theright-side rear shock absorber. Then put
the flange bolt through the canister
bracket. Finally, put the collar throughit from behind and temporarily fix thecanister on the frame.
CollarFlange bolt

○ Tighten the exhaust pipe flange nuts evenly
to the specified torque with care not tolet the canister and the exhaust pipe getout of the adjusted places.
Note: Be sure that you protect specified torque.
Exhaust pipe flange nut

Torque：10 ～ 12N・m（1.0 ～ 1.2kgf・m）

To the frame

PY○ Next, tighten the flange bolt on thecanister bracket to the specified torque.

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

Torque：22N・m（2.3kgf・m）○ Install the genuine exhaust system guard.
Reuse the genuine plus screws.

Note: Be sure that you protect specified torque.
Genuine screw○ Put the exhaust pipe flange through thepipe COMP., Insert the pipe COMP.
Into the joint part of the silencer
assembly, then insert the flange part into
the engine and temporarily fix it using
the genuine joint nut.
※ It is advisable to apply heat-resistantliquid gasket to the inserting portion.
Recommended: heat resistant liquid gasket
ThreeBond 1207B or the equivalent
Lock tight：5699 or the equivalentHeat proof liquid gasket

Torque：6N・m（0.6kgf・m）○ Check for interference among the genuine
exhaust system guard, the exhaust system,and the frame. If need be, loosen the screws
and nuts on each section to adjust thepositions to the extent that the adjusting
does not place too much strain on theexhaust system. Then fix them.

◎ You can see this instruction manual on our website as PDF data .
If this document hard to read, please download it from our website.
2024.1.1904-02-2308

/4