Instruction Manual for Kit
Contents
1. N Instruction Manual for sSReggtar Head Kit Item No0 00 00 0000 Applicable model names and the frame Nos Monkey Gorilla Z50J 1000001 1510400 6V Dax O ST50 1000001 6846265 Cub50 C50 N00002 V488897 C50 Z000002M Z069126M O C50 5000005 5121324 O C50 5200011 CD50 O CD50 1300001 1330600 O C50 3000001 3431226 L C50 4000001 4223783 O We are flattered that you have purchased one of our TAKEGAWA s products Please strictly follow the following instructions in installing and using the products Before fitting the products please be sure to check the contents of the kit Should you have any questions about the products please kindly contact your dealer Please be informed that in some cases the illustrations and photos may be different from the actual hardware Features We have improved the combustion efficiency through the change of the combustion chamber shape We have also improved air intake and exhaust efficiency with wider valve top diameters for intake and exhaust to 25 0 mm and 22 mm respectively along with a substantial change in the port shape Please read the following before installation 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 This kit is designed for exclusive use in the above mentioned applicable model nam2. head cover gasket 4 lefeside cylinder head side cover gasket 1 Mm slong A C 6 Manifold gasket 00 03 0009 Exhaust pipe gasket 00 01 0064 A speci BEC Otherwise we may not be able to accept your orders case please take them in the quantity packed YL Kit Contents Note The Gasket Kit varies depending on the kind of the cylinders Therefore carefully select and buy the kit not to make a mistake x Please note that in ordering repair parts be sure to quote the Repair Part Item No There are some parts however for which we are not in a position to accept your order in just the quantity to be used In this N Gasket set A for H and V cylinders 00 00 0000 000000000000 HO UNHU UUUUUUUUUUUUOUUUOO A cylinder with a marking on the top surface Symbol Part Name Repair Part Item No In packs of make vale ei 8 ehaust vee E TOOT OE BE D Valve stem seal cap 000 03 120 Fc E Vale spring inner seat 000 03 121 fF 1i Outer valve spring 01 10 01 Inner valve spring Valve spring retainer 000 03 084 Oo 1i TOOT OES Ca Sud bor 632 0 00 0085 2 ey e e SPECIAL PARTS UNAEZXANMA Co Ltd 3 5 16 Nishikiorihigashi Tondabayashi Osaka Japan TEL 81 721 25 1357 FAX 81 721 24 5059 URL ew wy Sep 01 07 Remove the original rocker arm shaft and rocker arm of an cylinder head O Apply a solution to the cam top and journal O Set t
3. left in the fuel tank always replace it with high octane gasoline Determine the heat value of a spark plug depending on how much it is burnt In vehicles originally with a resistor plug use a resistor plug Please be informed that what we can safely say is that the ignition system is compatible only with ours and stock ignition systems because no data is available with us on the compatibility with other ignition systems Therefore please never use other ignition systems which may cause technical troubles Since a stock clutch cannot be used a centrifugal filter will be unavailable So please install an outer oil filter Install an oil cooler when necessary Engine oil must be API SF or higher class such as an SAE 10W 40 15W 50 Upper limit of the engine revolutions is 12 000 rpm Please install a revolution counter to always keep the revolutions below the upper limit Change a sprocket with the one which corresponds to the engine output power and specifications This kit cannot perform on its own Refer to Engine Parts Recommended by TAKEGAWA on page 3 This kit is only compatible with those engine parts recommended by us So please replace the engine parts not recommended by us with those of our recommendations This product is designed for exclusive use on the closed course So take note that it is prohibited to drive your motorcycle on a public road after installation of this kit Drive your motorcycle at a
4. legal speed abiding by the laws 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 result in crank shaft damage and engine damage in the worst case 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 Please retain this Instruction Manual for future reference The following show the envisioned possibility of injuries to human bodies or property damages as a result of disregarding the following cautions O This product is designed for exclusive use on the closed course So take note that it is prohibited to drive your motorcycle on a public road after installation of this kit Drive your motorcycle at a legal speed abiding by the laws O Work only when the engine and muffler are cold at below 35 degrees Celsius Otherwise you will burn yourself Prepare right tools for the work Otherwise parts will be damaged or you will suffer injuries As some products and frames have sharp pointed or protruding portions please work with great care Otherwise you will suffer injuries E Always use new gaskets packings and the like Worn
5. ed parts could break the parts leading to accidents O When you notice something abnormal with your motorcycle while riding immediately stop riding and park your motorcyle in a safe place Otherwise the abnormality could lead to accidents 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 leading to accidents Check or perform maintenance of parts correctly according to the inspection procedures in the instruction manual or a service manual Improper checking or maintenance could lead to accidents Be sure to always use premium unleaded petrol Otherwise troubles such as knocking of an engine may cause accidents Cautions before riding About fuel Whenever regular gasoline is left in the fuel tank always replace it with high octane gasoline With this kit installation a centrifugal filter will be lost So please install a dry type clutch with an external oil filter or a special clutch Change of a sprocket The installation of this kit will increase the power of your vehicle So the use of a stock sprocket will result in severe wears of parts because of too low gear not only adversely affecting the engine life but also damaging the engine in the worst case Therefore please change the sprocket with the high geared one This kit cannot function on its own Referri
6. ep O1 07 O Adjustment of cam chain Adjust the valve clearance with Loosen an 8mm nut and adjust adjusting screws bolt A and then the cam chain will IN 0 08 when cold be adjusted automatically by the EX 0 08 when cold spring But in case the cam chain is not stretched tight keeping the loosened adjust bolt A as it is gradually tighten the adjust bolt B so that the cam sprocket and cam chain fit together even when the flywheel is turned O Tighten the adjust bolt A and then 8mm nut O Tighten the adjusting nut to the specified torque Caution Never fail to observe the specified torque T 10 N m 1 0 kgf m Caution Never fail to observe the specified torque T 8 N m 0 8kgf m Adjust bolt A wit O Attach the new F gasket of the kit to chain check the ignition timing A ts Ai ja a O Place the new right side cover a HERE ouge on the cylincer Hage gasket in the right side cover and i ek a M wee attach the right side cover to the Padseover and attach the gylindey cylinder head with two original head cover with original sealing bolts and tighten to the specified washer and flange bolt trom the torque right side eee head cover Caution Never fail to observe the O If you have adjusted the cam specified torque T 10 NU m 1 0 kgf m O Give the EEn over two turns counterclockwise and align the O mark on the cam sprocket wi
7. es and frame numbers only Please take note that this kit cannot be mounted on other types of motorcycles Installation of this kit requires engine removal and mounting crankcase disassembly and other work Please do the work with utmost care referring to the installation procedures in a HONDA genuine service manual for the relevant vehicle This instruction manual as well as HONDA s genuine service manual is prepared with those persons in mind who have basic skills and knowledge in tuning Therefore we recommend those who are technichally inexperienced or do not have enough tools to ask a technically reliable specialist shop for the work We shall be held free from any responsibility or compensation whatsoever for any glitch in the parts other than ours if the glitch takes place after the installation and use of the products You are kindly requested not to contact us about the combination of our products with other manufacturers A serial number is stamped on the cylinder head You may be requested to inform us of the number when ordering parts Some of bolts nuts dowel pins and packings will be reused However be sure to replace worn down or severely damaged ones with new ones Never use liquid packing It may plug the oil passage and in the worst case damage the engine Be sure to always use premium unleaded petrol And make sure to check what kind of gasoline is remaining in the fuel tank Whenever regular gasoline is
8. f 100 to 150 km O After the running in see if there is nothing unusual like strange sounds or blow by gas If something wrong is found disassemble the engine again to check every part of it Warning Never reuse the unusable parts N J Sep 01 07 N MEA AALER HUUUUUUUUUUUUO Reference data on bore up kit 88cc UU Wie OOO 00 00 cg L 00 00 0 00 000 an d UU Select a cam 0O HOUUU HOUUUUUUUUUU Select a V or H cylinder Ee U0UN XOOUUUGCUUDUUUUUUUEUOUUUOUUUUUUUUUUUUOUUUUUUUUUOUUUUUUUUood lf you have purchased a cylinder head kit only Item No 01 03 3001 please study to install these special parts referring to this reference data N Apr 16 07 J Ne
9. gle unit please be informed that selection sets are available to meet your combination demand depending on engine displacement etc Please study the required contents of the kit referring to the attached Reference data on bore amp stroke up kit Please contact your dealer for more details about the kit or enquiries Engine Parts Recommended by TAKEGAWA X This kit is only compatible with those engine parts recommended by us So please replace the engine parts not recommended by us with those of our recommendations Recommended Part Clutch e C CSCS Dve cune Monkey amp Gola CCSC S Carburetor Keihin PE28 Monkey amp Gorilla 106 124cc MIKUNI VM26 Monkey Gorilla amp Dax 889 124cc Oil pump Super oil pump kit 01 _ Cam chain Heavy duty cam chain kit 01 14 002 O Only in case of cylinder head kit on CECE Oil catch tank Only for Monkey amp Gorilla 09 04 031 In case head breather cap is used 09 04 032 About optional cam shaft We have prepared a few kinds of cam shafts compatible with this kit For your riding pleasure referring to the list below select a cam shaft to meet the engine displacement and uses Super street cam shaft 01 08 06 Packed together with bore up and bore stroke up _ awe ee J A2 Sep O1 07 f Gasket set A for old type cylinder 00 00 0000000000000000000000 000 0000 Wo Part Nare 1 Gvinder head COMP Sa 2 evinder
10. he cam shaft on the cylinder head of the kit Cah shaft Turn the camshaft so the IN and EX cam tops face the combustion chamber side OApply molybdenum solution to the rocker arm shaft Install the rocker arm and rocker arm shaft with the thread of the rocker arm shaft facing the outside O Attach an 8x14 dowel pin of the kit into a dowel pin hole on the cylinder Thoroughly degrease the upper surface of the cylinder Oln the case of a V H or S for SCUT cylinder attach a cylinder head gasket aa Note These ajinde have a marking on the cylinder head surface or its Item No is stamped on the fin side Item No stamped here stamped here In the case of a cylinder with no ltem No or stamped marking or a supplied cylinder coming with a green rubber gasket attach a cylinder head gasket black rubber packing and green rubber gasket The above applies only to the old type cylinder kits f accu the piston to be at Top Dead Center TDC install the cylinder head f Cylinder Head Installation Procedures Set the cylinder head cover gasket O Tighten the bolt on the cam chain guide roller to the specified torque Caution Never fail to observe the specified torque T 10 N m 1 0 kgf m on the cylinder head O Set the mark on the cylinder head cover at EX lightly apply Aluminum Special the heat resistant lubrica
11. ng is off the engine likely will malfunction seriously let alone fail to exhibit its original performance Therefore it is advisable to check and adjust the ignition timing without fail If you are technically unskilled at the work have your motorcycle checked by your motorcycle shop Attach a generator cover Caution Never fail to observe the specified torque T 70 11 NO m 70 1 1 kgf m 01 009 at the time of idling check that the F mark on the flywheel is aligned with the alignment mark on the crankcase Alignment mark F mark O Inject engine oil to the level specified by the relevant clutch kit Referring to the service manual attach a drive chain Sep O1 07 Loosen the breaker tightening screw and move the breaker plate bit by bit to adjust the timing O After the adjustment turn the crank shaft and set the position of the point so it has the widest clearance which please measure with thickness gauge Point clearance 0 3 0 4 mm In case the clearance is outside the specified limit replace the point O When the adjustment is over start the engine again Make sure that there is nothing unusual like abnormal sounds O If nothing unusual is detected carry out a shakedown of about 30 to 50 km and recheck the valve clearance Caution Do this work when the engine is cool Do the running in again o
12. ng to the attached sheet please purchase a bore up or bore stroke up kit for exclusive use in this kit This does not apply to the case where you have purchased a full kit Others Oil cooler The installation of this product increases the heat release value of the engine set off by the increase in power For a long time high load running 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 About a cam shaft If you have purchased a cylinder head Kit alone a special camshaft is needed separately Camshafts with two kinds of profiles are available from us Even if you have purchased a full Kit you can study to use those camshafts as optional extras in addition to the camshaft provided in the Kit For more information please refer to the attached sheet Upper limit of revolutions The upper limit of revolutions varies depending on the installed camshaft and other factors Install a tachometer in order to always drive your motorcycle at below the specified highest engine revolutions Take note that idling and sudden acceleration in the 1st and 2nd gears particularly tend to exceed the upper limit of revolutions Over revolutions will result in nonsmooth revolutions of the engine not only adversely affecting the engine life but also damaging the engine in the worst case f you have purchased a cylinder head as a sin
13. or damaged ones may cause engine troubles 4 Al Sep O1 07 The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the following cautions Those who are technically unskilled or inexperienced are required not to do the work Improper installation because of insufficient skill and knowledge could lead to parts breakage and subsequently to accidents Before doing work place the motorcycle on level ground to stablize the position of your motorcycle for safety s sake Otherwise your motorcycle could overturn and injure you while you are working O Always drive the engine in a well ventilated place and do not start the engine in an airtight place Otherwise you will suffer from carbon monoxide poisoning O As gasoline is highly flammable never place it close to fire Make sure that nothing flammable is near the gasoline It may cause a fire Always use a torque wrench to screw bolts and nuts tight and securely to the specified torque Improper torque could cause these parts to get damaged or fall off resulting in accidents O Never use any other parts than those specified by us The use of the unspecified parts may lead to parts breakage and consequent accidents If you find damaged parts when checking and performing maintenance of your motorcycle never reuse them but replace them with new ones The continued use of these damag
14. th the T mark on the flywheel gt Notch O Tighten the attached fangs bolts to the specified torque A caution Never fail to observe the specified torque T 8 NU m 0 8 kgf m f 5 y eee 7 P F a n r oo J O Attach a new O ring of the kit to the ye Engine Starting lt original tappet cap apply engine oil Make sure that the ignition key and to the O rings slightly and tighten gas cock are turned off me omg ie Speciice pes O Keep kicking the starter for a while Caution Never fail to observe the filithe Saqinevil circulates el apo ClieG TONUS around the engine TEAM 19 ME m AOST 10 at m O Attach a spark plug And slightly apply Aluminum Special to threaded portion of the plug and tighten it Caution Never fail to observe the specified torque Attach the plug cap to the spark plug O E to the service manual O Wipe off the dirt adhering to the mount an engine onto the frame engine Caution Never fail to observe the instructions in the service manual O Install a carburetor following the relevant carburetor kit instruction manual O Attach a drive sprocket Caution Never fail to observe the specified torque T 12 NO m 1 2 mal m Turn on the gasoline cock and ignition key to start the engine Warning Do the work in a well ventilated place Inspection and adjustment of ignition timing O If the ignition timi
15. ting agent to the threaded portion of the stud bolt and then attach a sealing washer and a nut Attach copper washers and steel washers at the lower left and hex nuts and cap nuts at the lower right at the prescribed positions when the engine viewed from the front Copper sealing washer Das Hex nut Sa R j gt ARA gt a lt A O Screw the nut of the stud bolt diagonally in a few steps to the specified torque ASCaution Never fail to observe the specified torque T 12 N m 1 2 kgf m cylinder and the cylinder head to the specified torque Caution Never fail to observe the specified torque a O Tighten side bolts both of the T 12 NU m 1 2 kgf m Attach the cam chain to the cam sprocket and install the cam sprocket to the cam shaft with a plate and three bolts O At this stage lightly apply Aluminum Special the heat resistant lubricating agent to the threaded portion of the bolt Align a T mark on the flywheel with an alignment mark on the crankcase and then align an O mark on the cam sprocket with an alignment mark on the cylinder head O Holding the crank shaft tighten the cap screw holding the cam sprocket to the specified torque A Caution Never fail to follow the specified torque T 10 Ni m 1 0 kgf m S
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