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Engine Complete KIT
Thank you for purchasing our Complete Engine.
This engine is one of our Engine Complete Series which we have designed and produced by using with years of our experienced product development and manufacturing know-how.
We are proud of that we guarantee customer satisfaction with such a lightweight and high power engine.
Before installing and using this product, please check the contents of the kit, read this installation instructions carefully and understand them completely.
１．Please Note: Illustrations and photos may vary from actual hardware.
２．The service and repair information contained in this manual is intended for use by qualified, professional technicians. Any person who does not have sufficient technique, knowledge, proper tools and equipment will never
work. Be sure to ask specialty shops or professional mechanics.
Poor technique and lack of knowledge may cause the maintenance problems or damage parts.
３．This product is intended for use ONLY in closed racing course. Never use this product on public roads.
４．This kit is compatible with the above mentioned compatible models ONLY. Note: Do Not use this product for other models than listed above.
５．The cylinder length of this complete engine is longer than that of the stock engine.
It is impossible to install on stock motorcycle chassis. NOTE: Modification of the chassis is required.
６．Please note that mainly because of improvement in performance, design change, and cost increase, the product specifications and prices are subject to change without prior notice. We shall be held free and harmless
from any and all liabilities or claims for any defects of the parts / the product after installation, and use, and/or any other products/parts.
７．We do NOT accept any claims due to the parts for racing use only. Except, any requests for the return or repair of goods purchased from TAKEGAWA must be made within one month of receipt of goods against defects
in workmanship and/or materials originally caused by ONLY our failure. No returns or repairs will be accepted after one month. However, we DO NOT accept our products which are NOT installed in the right way and/or
DO NOT used properly.
We are not responsible for any expenses for repair or replacements.
NOTE: When you use for racing, we shall be held free and harmless from any and all claims.
８．These instructions should be retained along with this product.
: Spec.SUPER HEAD
(4SM-148)
Important Notice
‑A1‑
4VALVE + R
☆Primary kick starter
☆ SUPER HEAD 4VALVE + R -148
☆ 4-Speed
Item No.：０１―００―９２０２
Compatible models
：Z50J -2000001〜
Monkey / Gorilla
：AB27-1000001〜 1899999
Sep./12/ 12
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Related Manuals for Takegawa 01-00-9202
Summary of Contents for Takegawa 01-00-9202
- Page 1 from any and all liabilities or claims for any defects of the parts / the product after installation, and use, and/or any other products/parts. ７．We do NOT accept any claims due to the parts for racing use only. Except, any requests for the return or repair of goods purchased from TAKEGAWA must be made within one month of receipt of goods against defects in workmanship and/or materials originally caused by ONLY our failure.
- Page 2 (Otherwise, the malfunction could lead to accidents.) ・Carry out inspection and maintenance of your motorcycle correctly according to the instructions and guidelines in the service manuals. (Use TAKEGAWA-recommended fuel and engine oil.) ・Fuel must always be high-octane gasoline. (Otherwise, troubles such as engine knocking may cause accidents.) ・When driving a bike, a driver must always wear a helmet securely.
- Page 3 Features ●Use of Roller Rocker Arm: ● Use of Wet Multiple-Disk Clutch: ◇We have used roller bearings in the slipper instead of a conventional slipper type rocker arm. The use of the ◇We have installed a multiple-disk clutch with 5 disks onto the transmission main shaft so it can respond to roller bearings helps to reduce friction and makes possible the smooth and constant tight grip on a cam profile even high output powers.
- Page 4 〜 Kit contains 〜 Part Name Repair Part Item No. In packs of １ Engine COMP. Spark plug, ER8EH NGK-ER8EH Intake manifold Socket cap screw, 6 x 25 Socket cap screw, 6 x 15 06171-4SM-T00 Norma Torro Band Inlet pipe gasket Socket set screw, 6 x 15 Exhaust pipe gasket 00-01-0064 Clutch cable COMP., 910 mm 22870-086-T00 Braided hose, 8 x 1 m 00-07-0070 Hose clamp, 13.1 Hyper CDI 05-03-0003 １４ ５ １５ ３ Thumb screw 00-01-0254 ６ 00-01-0255 Snap ring, 6mm Rebuilt gasket set 06111-4SS-T20 ８ ７ Spark plug cap COMP.
- Page 5 Main Reference Value Inspect and Adjust 4-cycle gasoline Items Frequency Refer to page Type Displacement 147.6cc Clean and Inspect Spark Plug Every 200km P-C1 Number of cylinder and arrangement Horizontal single cylinder Inspect Valve Clearance Every 500〜600km P-C2,C3 Cooling method Air-cooling Change Engine Oil Every 1000〜2000km P-C1 Valve train Chain drive and SOHC Adjust and Inspect Carburetor Each time Depend on Carburetor type Replace Oil Filter Every 1500〜2000km P-C2 Chamber design Pentroof (Hemispherical) type Bore and Stroke 59mm x 54mm Adjust Clutch Cable Every 250km P-C2 Compression ratio 13.0:1 Inspect Clutch Friction Disc Every 1000km See Service Manual Inspect Piston and Piston Ring...
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Page 6: Precautions Of Use
〜 Precautions of Use 〜 About upper limit of revolution: About the specifications of motorcycle to equip ◇The upper limit of revolutions varies depending on the installed camshaft and other factors. Please install a ◇ The cylinder length of this complete engine is longer than that of the stock engine. revolution counter to make sure that you drive the engine at revolutions below the upper limit, referring to the It is impossible to install on stock motorcycle chassis. - Page 7 Also, the engine output will vary significantly depending on the used exhaust system, length of inlet pipe, carburetor diameter, compression ratio, ignition timing, fuel or the natural phenomenon such as ambient temperatures or atmospheric pressure. 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 Sep./12/ 12 ‑A7‑...
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Page 8: Installation Instructions
〜 Installation Instructions 〜 ☆ Please Note: Illustrations and photos may vary from actual hardware. ☆ Before starting the installation, please prepare the relative service manual and necessary tools for the motorcycle. ☆ And prepare necessary optional parts as well. For details, please see the attached sheets. ☆... - Page 9 ○Attach the flange bolt to the release arm, and tighten ●Installation of carburetor: ☆ In the case of PE28: ○ Attach an air filter, which please secure by the bolt to the specified torque, pressing the arm. tightening a band. ○Route the supplied throttle cable along the frame just Fits only the Monkey ○...
- Page 10 ☆In the case of VM26: ○ Adjust the free play at the throttle grip to be about ○ Dispose of the blow-by gas from the crankcase by ●Engine oil 5 mm by turning the adjuster of the throttle cable. yourself. ○Remove the top cover from the carburetor, and pull ○...
- Page 11 ○ Stop the engine once. ●Installation of drive chain ○ Install the drive chain referring to a genuine service ● Start engine Wait for a few minutes and keep the motorcycle manual or instruction manual for the relative rear fork. ○...
- Page 12 ◎Relevance of Front Fork and Tire ● In the case of not installing the thermo unit ◎ About Optional Clutch Parts: In case an oil cooler is not installed: ○φ 27Upright Front Fork (Installation of thermo unit) １．Detach the thermostat hole cap, and fit a NEVER install a thermo unit or an oil hole plug.
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Page 13: Engine Stop Switch
Blue/Yellow PIckup pulse 黒/赤 黒/赤 点火用AC出力 Black/Red Black/Red Ignition AC output 若葉/赤 若葉/赤 ニュートラルスイッチコード Light Green/Red Light Green/Red Neutral Switch TAKEGAWA C.D.I. Engine Stop Switch Black/White Black/Yellow Black/Red Blue/Yellow Green ON:STOP Ignition Coil Blue Black/Red /Yellow Yellow 1 Green Yellow 2... -
Page 14: Inspections And Adjustments
〜 Inspections and Adjustments 〜 CAUTION Be sure to use a torque wrench and strictly keep the specified torque. The inspections and adjustments are intended for use by qualified professional mechanics. Be sure that any person who does not have the proper WARNING technique, experiences and knowledge will never work. - Page 15 ○ Apply a thin coat of engine oil to the O-ring on the oil ●Adjust the Clutch Cable ●Adjust the Valve Clearance ● Change of Oil filters: filter cover, attach an oil filter and oil filter cover, and ○ Inspect the free play of clutch lever. ○...
- Page 16 ○ Turn the flywheel and adjust to the top dead ○ Tighten the adjust nut to the specified torque. ○ Tighten the adjusting nut to the specified torque. ○Re-install the generator cover and tighten to the center(TDC). specified torque. Caution : Be sure to follow the specified torque.
- Page 17 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: When the air-fuel mixture is too lean: ・The explosion sound with a dull thud continues intermittently.
- Page 18 09-02-0232 (Gray metallic anodized) Outer length: 810 mm 09-02-0231 (Black anodized) 09-02-0233 (Gray metallic anodized) φ 29 φ 29 00-03-0210 00-03-0211 For more information, please refer to our parts catalog, or log onto our Web site at URL http://www.takegawa.co.jp Sep./12/ 12 ‑D1‑...
- Page 19 2.13 2.20 2.27 2.33 2.40 1.43 1.50 1.56 1.62 1.68 1.75 1.81 1.87 1.93 2.00 2.06 2.12 2.18 2.25 For more information, please refer to our parts catalog, or log onto our Web site at URL http://www.takegawa.co.jp Sep./12/ 12 ‑D2‑...
- Page 20 02-01-5052 Thus, the thermo unit serves to prevent the overcooling and to keep the oil at a fixed temperature. For more information, please refer to our parts catalog, or log onto our Web site at URL http://www.takegawa.co.jp Sep./12/ 12 ‑D3‑...
- Page 21 L / R Front Fork Set ００―０６―００２０ ０６―０９―０２１１ (3.5J) L / R Front Fork Set ０６―０９―０２１２ (2.5J) ０６―０９―０２１３ (2.75J) For more information, please refer to our parts catalog, or log onto our Web site at URL http://www.takegawa.co.jp Sep./12/ 12 ‑D4‑...
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