Z-Style Exhaust system Instruction Manual（MLIT / JMCA Certified）

COItem No.
：０４−０２−２３０６
Applicable to ：Monkey (FI)Frame No.

：AB27-1900001 〜

Thank you for purchasing one of our TAKEGAWA’s products. Please strictly follow the instructions in installing and using the products. Before fitting theproducts, please be sure to check the contents of the kit. If you have any questions about the products, please kindly contact your local TAKEGAWA
dealer.
Before installation, please read this instruction manual carefully and understand the instructions fully.
Enjoy the distinctive sound and performance with our exhaust system.

◎ Please note: Illustrations and photos may vary from the actual hardware.

〜 Features 〜PY○ Our genuine-style exhaust system can be installed with Monkey’s genuine exhaust system guard.
It improves the performance while remaining the original look of the Monkey.
○ We have adopted our canister body and exhaust pipe, both made of stainless, to improve the appearance and durability.
○ Our canister with catalyzer passed the Japanese Emission Control, enforced in 2006.
○ The Japanese MLIT / JMCA certification, enforced in 2010, is acquired.

Please read the following instructions before installation.

◎ The following show the envisioned possibility of injuries and damages to human bodies, and physical loss or damage as a result of disregarding thefollowing cautions.
◎ 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.
◎ 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 refrain from combined use of this kit with with any other part than the specified parts.
◎ Though a genuine exhaust system guard can be installed as it is, modification to it is necessary as the exhaust system guard and vehicle body may
interfere with each other but depending on the slight difference in guard-mounting portion and its parts and vehicle body.
◎ This product is designed for exclusive use with stock kick starter arm. (TAKEGAWA’s kick starter arm will interfere with a genuine exhaust systemguard.)◎ Installing the wire-type Dry Clutch Kit (02-02-0143), please use the Hydraulic Clutch Kit (02-02-0144). This product CANNOT be installed with thewire-type Dry Clutch Kit (02-02-0143).

CAUTION

The following show the envisioned possibility of injuries and damages to human bodies, and property loss as a result ofdisregarding the following cautions.

・Please drive safely and keep to the traffic regulations.
・Work only when the engine and the exhaust system are cool to avoid getting burn injury.
・Prepare appropriate tools and work properly to avoid the breakage of parts or injuries.
・Always use a torque wrench to tight 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.
・Do water washing of a 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 considerate enoughnot 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 exhaust system andget burned or suffer property loss.)・Before riding, always check if every screws and bolts are tighten properly.
(If you find loose ones, screw them securely up to the specified torque to avoid parts coming off.)
・This is designed for exclusive use with stock kick starter arm. TAKEGAWA’s kick starter arm CANNOT be used with this product.
・The Japanese MLIT / JMCA Certification is acquired when vehicles are ready for delivery from the manufacturer.

‑1‑May./13/ 10

WARNING

The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding thefollowing 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.)
・Never look into the exhaust outlet when the engine is running. (Otherwise, you will suffer from carbon monoxide poisoning or lose your sight.)
・When you notice something wrong 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 lean angle, and run with care not to lean the vehicle more steeply than the maximum lean 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 running or for a while after the engine stopped. Therefore, neverCO

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 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.)
・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 canbe 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 touchthe exhaust pipe when pressing down on the rear brake pedal.
DO NOT wear loose clothing or sandals when riding on the vehicle. You must wear properly to avoid burns or any accidents.

PY◎ Please be informed that, because of improvement in performance, design changes, and cost increase, the product specifications and prices are
subject to change without prior notice.
◎ We do not have any information or service data on the combination use of our products and other manufacturer’s products.
◎ This manual should be retained for future reference.

〜 Kit Contents 〜

２１３No.
Parts Name
1 Canister assembly
2 Exhaust pipe
3 Exhaust gasket

Qty Repair Part Item No. In packs of1
1 118200-FM1-T00
11 00-01-0064
2※ Please order repair parts with the Repair Part Item No.
Without the repair part item No., we may not be able to accept your orders.
Some parts are only available as a set. In this case, please order them with theset number.

‑2‑May./13/ 10

〜 Installation Procedures 〜
Stabilize the vehicle with a maintenance stand or the like in a safe and level place during work.

● Genuine Exhaust System
Removal●Genuine Exhaust System Guard
RemovalCO１．
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.

１．Detach the exhaust system guard and exhaust
pipe guard from the just-removed genuine
exhaust system.

２．Unfasten the hex’ bolt which is fixing theexhaust system.

Exhaust system

３．Remove the exhaust system from the vehicle
body.

１．Insert and install the included exhaust pipe
gasket to the exhaust port.

２．Unscrew all Philips screws which are fixing
the exhaust pipe guard to the exhaust system.
Keep those screws for re-use.
If the screws are worn or damaged severely,replace them with new ones.

Gasket２．Temporarily install the canister assemblyto the frame. Put the rear end of the canister
pipe through behind the upper part of the rightside rear shock absorber and mount theJoint nutBolts● Z-Style Exhaust SystemInstallation

CoverProtector

PY
Screws / Washers

canister pipe temporarily on the frame with astandard bolt.

ScrewsCAUTION: Philips screws may be very tightly
screwed, so unscrew them withenough care not to damage theirheads.
３．When installing the genuine exhaust system
guard, the bracket to equip the exhaust pipe
guard can be seen. So cut off the excess ofthe exhaust system guard as shown in the photo
below.

３．After inserting the exhaust pipe into the joint
on the silencer assembly, insert its flange into
the engine.
※We recommend to apply heat-resistant liquidgasket to the inserting portion.
(ThreeBond 1207B or the equivalent.)

Apply the liquid gasket here.

４．Remove the old exhaust pipe gasket if
remaining in the exhaust port.

Cut off this part

Gasket・If you cut off the excess, we recommend to
give a touch-up to the cut surface with a heatresistant paint to prevent the surface fromrusting.

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４．Put the exhaust pipe flange through the studbolt of cylinder head and fix it temporarily
with the genuine nuts.

８．Install the genuine exhaust system guard.
To avoid the screws coming off with thevibrations of the vehicle, we recommend to apply
the Lock Tight 241 or the equivalent.

CO

５．Check the clearance between the canister’s
exhaust pipe and the rear fender, and thenadjust the positions of the canister and theexhaust pipe so that they do not interferewith each other.

６．Tighten the exhaust pipe flange nuts evenly
to the specified torque with care not to let thecanister and the exhaust pipe get out of theadjusted places.
Torque : 12 N・m (1.2 kgf・m)
Caution: Always keep the specified torque.

９．Install an exhaust pipe cover onto the exhaust
pipe in the reverse order of removal.
To avoid the screws coming off with thevibrations of the vehicle, we recommend to apply
the Lock Tight 241 or the equivalent.

１１．If a standard kickstarter arm interferes withthe exhaust system guard, change thelocation of the serration until the kickstarterarm does not interfere with the guard, andinstall the kickstarter arm.

１２．Peel the protecting film off the certification
plate.

● Final Checking
１．Start the engine in a safe and well-ventilated
place, and check for exhaust leak orinterference.
２．After stopping the engine and after each partPY

has cooled down to the normal temperatures,
re-tighten all screws and nuts to thespecified torque.

１０．Make sure the genuine exhaust system
guard, the exhaust system and the frame
are all in good condition. If necessary, loosen
the screws and nuts on each section toadjust the position of the exhaust system.
DO NOT apply unnecessary force. Moreover,when the exhaust system guard, seat bracket
and canister interfere with each other, modify
or deform the interfering portions to maintainthe proper clearance.

● Addition○ If you have installed our Special Clutch Cover,the exhaust system guard and clutch releasearm will interfere. Before installing the exhaustsystem guard, modify the interfering portions.
If you have cut off the interfering portions, werecommend to apply touch-up to the cutting
surface with the heat-resistant paint to preventfrom rusting.

７．Then, tighten the standard bolt on thecanister bracket to the specified torque.
Torque : 29 N・m (3.0 kgf・m)
Caution: Always keep the specified torque.

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‑4‑May./13/ 10