Z-Style Exhaust system (TYPE
Contents
1. N Z Style Exhaust system TYPE 2 Instruction Manual tem No QOUO OU OU000g Applicable to Monkey Gorilla Frame No Z50J 1300017 AB27 1000001 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 Features O 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 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 the following cautions We shall be held free from any kind of warranty whatsoever of products o2. injuries to human bodies as a result of disregarding the following cautions Always drive the engine in a well ventilated place and do not switch the engine on in an airtight place Otherwise you will suffer from carbon monoxide poisoning O 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 with n
3. 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 A Qt 25 10 f Genuine Exhaust System Removal O0 O Unscrew the bolts on the air cleaner stay O0 O After removing two collars on the exhaust TT a aa aeaa E Installation Procedures Stabilize the vehicle with a maintenance stand or the like in a safe and level place during work Genuine Exhaust System Guard Removal O O Remove the exhaust system guard from the just removed genuine exhaust system O0 O Unscrew all plus screws which are fixing the exhaust system guard to the exhaust system Keep those screws for re use If the screws are worn or damaged severely replace them with new ones N CAUTION Work only when the engine and flange remove the exhaust system from the the exhaust system are cool body by pulling it outward CAUTION Plus screws may be very tightly screwed so unscrew them O O Loosen the band which is clamping the carburetor and the air cleaner and remove the air cleaner with enough care not to damage their heads O O Though the genuine exhaust system guard can be installed as it is the bracket which is fixing the guard on the exhaust pipe gets exposed without processing Therefore cut off the unnecessary part CAUTION Once the bracket is processed or cut off the guard on the exh
4. alent O O Peel the protecting film off the JMCA plate and clean the dirt sticking on the exhaust system completely SPECIAL PARTS Co Ltd 0O O Put the exhaust pipe flange through the stud ausam l 3 5 16 Nishikiorihigashi Tondabayashi bolt of the cylinder head and fix it temporarily with the nuts which were used to fix the genuine exhaust system Osaka Japan TEL 81 721 25 1357 FAX 81 721 24 5059 URL http www takegawa co jp 0 O Install the genuine exhaust system guard ae Cct 25 10
5. aust pipe of the normal exhaust system will be rendered not installable any more L ey i N wah sell O O Unfasten the nut on the back side of the exhaust system O O Remove the old exhaust pipe gasket remaining in the exhaust port Cut off this part O UUnfasten two nuts on the exhaust pipe flange O O If the exposing portion is cut off it is advisable to give a touch up to the cut surface with a heat resistant paint to prevent the surface from rusting Keep them for re use If the nuts are worn or damaged severely replace them with new ones O O Reinstall the removed air cleaner in the order opposite to its removal On to a 12V motorcycle never forget installing earth wires Torque 8 10 N m 0 8 1 0 kgf m O O Unfasten the hex bolt which is fixing the exhaust system 3 Cct 25 10 Z Style Exhaust System Installation Final Checking O 0O Insert and install a kits exhaust pipe gasket O O Check the clearance between the exhaust pipe O Start the engine in a safe and well ventilated to the exhaust port of canister and the rear fender and then place and check for exhaust leak or adjust the positions of the canister and the interference exhaust pipe so that they do not interfere with O O After stopping the eng
6. ew 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 suchas in sandals It could lead to burn or accidents 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 in racing 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 Kit Contents No Pars Name Oty Repair parts tem No in packs of TB200 ABS TO0 91139 AB9 TOO a Fonge bok BGO 1 ooo S x Please order repair parts with the Repair Part Item No Without the repair
7. ine and after each part each other has cooled down to the normal temperatures re tighten all screws and nuts to the specified torque O0 O Temporarily install the canister assembly to the vehicle in the following order First pass the rear end of the canister pipe from behind the upper part of the right side rear shock absorber Then put the flange bolt through the canister bracket Finally put the collar through it from behind and temporarily fix the canister on the frame O O Tighten the exhaust pipe flange nuts evenly to the specified torque with care not to let the canister and the exhaust pipe get out of the adjusted places Torque 10 12 N m 1 0 1 2 kgf m Collar Flange bolt l To the frame 0 O O Next tighten the flange bolt on the canister bracket to the specified torque Torque 23 N m 2 3 kgf m Reuse the genuine plus screws O O After inserting the exhaust pipe into the joint on the canister assembly insert its flange into the engine O O Check for interference among the genuine exhaust system guard the exhaust system and the frame If need be loosen the screws and n uts on each section to adjust the positions to the extent that the adjusting does not place too much strain on the exhaust system Then fix them It is advisable to apply heat resistant liquid gasket to the inserting portion ThreeBond 1207B or the equiv
8. regarding the following cautions 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 AS some products and frames have sharp edges or protruding portions work with your hands protected to avoid injuries O 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 considerate enough 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 exhaust system 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 O This exhaust system is designed for exclusive use with a stock kick starter arm TAKEGAWA s kick starter arm will interfere with the genuine exhaust system guard S Z e Cet 25 10 AN WARNING The following show the envisioned possibility of human death or serious
9. ther than this product if the any defect 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 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 partially exposed This product is designed for exclusive use with a stock kick starter arm In case of our kick starter the arm will interfere with the genuine exhaust system guard This product cannot be used together with a wire type Dry Type Clutch Kit of 02 02 0143 For the installation of the said Kit the installation of a Hydraulic Clutch Kit of 02 02 0144 is necessary 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 position or angles of canister s end pipe or rear shock absorber Be sure to check the size by yourself before installation The following show the envisioned possibility of injuries and damages to human bodies and property loss as a result of AN CAUTION g p y J g property dis
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