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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.
Please ask for cylinder head maintenance by our factory.
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.
:
Important Notice
‑A1‑
☆Secondary kick starter engine
☆ DESMO-124
☆ TAF5SP (Super Street)
☆Special Clutch (wet)
Item No.：０１―００―９４３０
Compatible models
：Z50J -2000001〜
Monkey / Gorilla
：AB27-1000001〜 1899999
Nov./29/ 12
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Related Manuals for Takegawa DESMO TWINCAM 4V
Summary of Contents for Takegawa DESMO TWINCAM 4V
- 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 ●About our DESMO head ●Use of Lightweight Outer Rotor ACG ◇ Most 4 stroke combustion engines use a camshaft and a valve spring to open and close the valves, but the ◇SS-outer rotor is equipped as standard .Rotor body is a compact design and it weighs 536g. The best ignition DESMO structure uses a specially shaped camshaft that forces the valve open and shut.
- Page 4 〜 Kit contains 〜 Part Name Repair Part Item No. In packs of １ Engine COMP. Spark plug, ER8EH NGK-ER8EH Intake manifold １ Socket cap screw, 6 x 20 Socket cap screw, 6 x 15 06171-D4H-T00 Norma Torro Band Inlet pipe gasket Exhaust pipe gasket 00-01-0064 Clutch cable COMP., 910 mm 22870-181-T00 Braided hose, 8 x 1 m 00-07-0070 Hose clamp, 13.1 Spark plug cap COMP. 30700-DSM-T00 Plug cord joint 00-01-1012 High tension cord, 500 mm 00-01-1043 Hyper CDI 05-03-0003 １４ ９ １０ Head cover gasket set 06111-DSM-T00 ３ Plug socket, 13 mm 00-00-0247 Ball point driver, 4 mm ２...
- Page 5 Main Reference Value Inspect and Adjust Type 4-cycle gasoline Items Frequency Refer to page Displacement 123.7cc Clean and Inspect Spark Plug Every 200km P-C1 Number of cylinder and arrangement Horizontal single cylinder Inspect Valve Clearance Every 500〜600km Cooling method Air-cooling Change Engine Oil Every 1000〜2000km P-C1 Valve train Adjust and Inspect Carburetor Each time Depend on Carburetor type DOHC(desmodromic) valve, chain / gear drive. Chamber design Pentroof (Hemispherical) type Replace Oil Filter Every 1500〜2000km P-C2 Bore and Stroke 54mm x 54mm Adjust Clutch Cable Every 250km P-C2 Compression ratio 12.5 : 1 Inspect Clutch Friction Disc Every 1000km See Service Manual Inspect Piston and Piston Ring Every 1000km...
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Page 6: Precautions Of Use
Due to large displacement engine, blow- by gas volume may increase. Larger capacity catch can are highly recommended. (approx 500 cc) Rearsets: ◇ To use rearsets, you may need to modify the drive sprocket cover. 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 Nov./29/ 12 ‑A6‑... -
Page 7: Installation Instructions
〜 Installation Instructions 〜 ☆ 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. ☆ Caution: This installation instructions are for the models which this complete engine can be equipped. ☆... - Page 8 ○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 9 ☆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 10 ●Installation of drive chain ● Install the exhaust system ● Start engine ○ Stop the engine once. Wait for a few minutes and keep the motorcycle ○ Check that the ignition key and gas cock are turned ○Attach a supplied exhaust pipe gasket to the exhaust ○...
- Page 11 ● In the case of not installing the thermo unit ◎ About Optional Clutch Parts: ◎Relevance of Front Fork and Tire In case an oil cooler is not installed: (Installation of thermo unit) １．Detach the thermostat hole cap, and fit an oil hole ○φ...
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Page 12: 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 13: 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 14 ○ Apply a thin coat of engine oil to the O-ring on the oil ●Adjust the Clutch Cable ● Change of Oil filters: filter cover, attach an oil filter and oil filter cover, and ○ Inspect the free play of clutch lever. ○...
- Page 15 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 16 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 Nov./29/ 12 ‑D1‑...
- Page 17 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 Nov./29/ 12 ‑D2‑...
- Page 18 For more information, please refer to our parts catalog, or log onto our Web site at through the bypass passage. When the oil temperatures rises to more than 70 degrees, the valve opens to let the oil flow to the oil cooler. URL http://www.takegawa.co.jp 02-01-5052 Thus, the thermo unit serves to prevent the overcooling and to keep the oil at a fixed temperature.
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Page 19: Front Fork
Tubeless wheel (10-inch) ０６―０２―００１５ ０６―０１―０７２３ Top Bridge & Stem L / R Front Fork Set ０６―０９―０２１１ (3.5J) 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 Nov./29/ 12 ‑D4‑...
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