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Hyper S-Stage eco Instruction Manual
・Thank you for purchasing one of our products.
 Please strictly follow the following instructions in installing and using the kit.
・Before installing the kit, please be sure to check the kit contents.
 Should you have any questions about the kit, please contact your local motorcycle dealer.
◎ Please note that, in some cases, the illustrations and photos may vary from the actual hardware.
Be sure to replace a spark plug with a supplied CR8HSA. And at a later stage, choose and use a right spark plug with the right
number, depending on the degree of burning of the spark plug electrode section.
The installation of this Kit will increase the power of your engine. So with the stock sprocket, every hardware will get worn out
soon because of too low gear, not only adversely affecting the engine life, but also possibly breaking the engine in the worst
case. Therefore, judge the right type of a driven sprocket, using the supplied drive sprocket. And make the gear ratio high.
※The driven sprocket is not included in the Kit.
◎ We do not take any responsibility for any accident or damage whatsoever arising from the use of the kit not in conformity with the instructions in the  
 manual.
◎ 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.
◎ If you make modifications to any product of the kit, we shall be held free from any guarantee of the product.
◎ You are requested not to contact us about the combination of our products with other manufacturers'.
◎Please note that this kit is designed for exclusive use in the above-mentioned fitting models and frame numbers only and that it cannot be mounted on any
 other models.
◎ For installation, please prepare suitable tools and work with reference to the installation instructions with enough care. Besides, this instruction manual,
 as well as a HONDA's service manual, is prepared with those persons in mind who have basic skills and knowledge. Therefore, we recommend those
 who are technically inexperienced or do not have enough tools to ask a technically-reliable specialist shop for the work.
◎ This piston designed for regular gasoline and standard ignition timing and we don't recommend changing timing advanced.
◎ Bolts, nuts and dowel pins will be reused. However, be sure not to use the worn-down or severely-damaged ones, which please do replace with new
 ones.
◎If you use a stock carburetor, do not remove the air cleaner box or air cleaner elements. If you change the carburetor, please do the setting to match  
 various conditions and specifications of your motorcycle. Disregarding of these instructions will result in engine troubles and serious accidents.
◎ Never running rain condition with this included air filter.
The following show the envisioned possibility of injuries to human bodies and property damage as a result of disregarding the
CAUTION
following.
・Always try to drive your motorcycle at legal speed, abiding by the laws.
・Work only when the engine and muffler are cool. (Otherwise, you will get burned.)
・Do the installation with right tools. (Otherwise, breakage of parts or injuries to you may take place.)
・Always use a torque wrench to screw bolts and nuts tight and securely to the specified torque.
 (Otherwise, these parts may get damaged or fall off, resulting in accidents.)
・As some products and frames have sharp edges or protruding portions, please work with your hands protected. (Otherwise, you will suffer injuries.)
・Before riding, always check every hardware like screws for slack. If you find slack ones, screw them securely up to the specified torque.
 (Otherwise, improper tightening may cause parts to come off.)
 ※ Be sure to fully tighten the cylinder head to the specified torque.
・Always use new gaskets and packings. And check those parts, to be reused, for wear and damage. If you find worn or damaged parts, replace them
 with new ones.
The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the
WARNING
following warnings.
・Always try to drive your motorcycle at a legal speed, abiding by the laws.
・Always start the engine in a well-ventilated place, and do not turn on the engine in an airtight place.
 (Otherwise, you will suffer from carbon monoxide poisoning.)
・When you notice something abnormal with your motorcycle while riding, immediately stop riding and park your motorcyle in a safe place to check
 what has gone wrong. (Otherwise, the abnormality could lead to accidents.)
・Before doing work, make sure your motorcycle is secure on level ground for safety's sake.
 (Otherwise, your motorcycle could overturn and injure you while you are working.)
・Check or carry out maintenance of your motorcycle correctly according to the procedures in the instruction manual or service manual.
 (Improper checking or maintenance could lead to accidents.)
・If you find damaged parts when checking and performing maintenance of your motorcycle, 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 accidents.)
・As gasoline is highly flammable, never place it close to fire. Make sure that nothing flammable is near the gasoline. Since vaporized accumulation
 of gasoline is at high risk of explosion, work in a well-ventilated place. (Otherwise, it may cause a fire.)
Notice about spark plug
Notice about sprocket
Read all instructions first before starting the installation.
‑ 1 ‑
0 1 − 0 5 − 0 0 8 9
Item No.
Z50J-2000001 〜
Monkey, Gorilla
AB27-1000001 〜 1899999
Dec./13/ 12

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Summary of Contents for Hyper S-Stage eco 01-05-0089

  • Page 1 Hyper S-Stage eco Instruction Manual ・Thank you for purchasing one of our products. 0 1 − 0 5 − 0 0 8 9 Item No.  Please strictly follow the following instructions in installing and using the kit. Z50J-2000001 〜 Monkey, Gorilla ・Before installing the kit, please be sure to check the kit contents.
  • Page 2: Kit Includes

    ◎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. ◎ This manual should be retained for future reference. Lesson ◇ Bolts and nuts will get loose when turned counterclockwise,and tighten when turned clockwise. ◇...
  • Page 3 Dec./13/ 12 ‑ 3 ‑...
  • Page 4 Removal of standard 2. Remove a fuel tank. 3. Remove the carburetor. hardware 1. Remove a seat. Clamp Wire harness ◇Remove a top cap and pull out a throttle valve, from the ◇Move the wire harness so it sits under the frame.  carburetor.
  • Page 5 5. Remove a front fender. ◇Remove the head cover. (If it does not come off easily, ◇Remove two hex bolts on the reverse side of the front  strike it lightly with a plastic hammer, and it will come Open-end wrench, 8 mm  fender by turning them counterclockwise.
  • Page 6: Left Side

    16.Remove cylinder gasket, rubber   Right-side ◇Arrange the positions of piston ring-end gaps to Left-side crankcase crankcase mesh with each other.   packing and dowel pin. Letter Cylinder gasket Top ring gasket Letters ◇While removing the cylinder, the cam chain guide  roller will come out, which please remove.
  • Page 7 ◇You can rather easily install it by pressing it into the   ◇Fix a second ring. ◇Install the guide roller bolt.  piston with a screwdriver, but taking care not to ◇Pressing the tire, install the cylinder.  (Tighten it only finger tight at this point.)  damage the piston with the screwdriver.
  • Page 8: Installation Of Cylinder Head

    5. Installation of cam sprocket. Notch Hex nut ◇Install the supplied camshaft in the reverse order of ◇Hold the cam chain by sticking the screwdriver through  removal.  the cam chain into a middle hole on the camshaft so the ◇Align the “T” mark on the flywheel with the notch on  Apply clean engine oil to the camshaft and camshaft  cam chain will not fall into the cylinder.
  • Page 9 7. Installation of cylinder-head left-side 9. Installation of stock muffler.  cover. ◇Holding the flywheel, tighten up three cam sprocket ◇While tightening a rocker arm’s tappet screw, tighten ◇In installing the muffler, route the tail pipe inside the  bolts.  the tappet nut to the extent that a 0.05 mm thickness    rear shock absorber first, and then set the flange to  Tool to use  gauge, placed between the tappet screw and the valve...
  • Page 10 10. Installation of front fender. Throttle cable 遊びが多く なる More free play アジャスタ ー Adjuster 六角ナッ ト Hex nut ◇Fasten two hex bolts on the reverse side of the front Less free play ◇Remove a top cap of carburetor, spring and throttle   ◇Connect the inner cable to the throttle pipe.
  • Page 11 ◇Install the fuel tank onto the frame with a bolt. ◇Applying the rear brake, unfasten two bolts.  Tool to use  Tool to use   Offset box wrench, 10 mm   Socket, 10 mm  Caution: Apply the specified torque.   Extension (short)  Torque: 12 N・m (1.2 kgf・m) ◇Tighten two nuts on the rear shock absorber.
  • Page 12  ※With change of a drive sprocket, a driven sprocket is also changed and high gear-ization of a sprocket is performed.  ※A driven sprocket changes with clutch form or tire size. Please make a lower table reference. ★A hyper-S stage kit C type recommendation sprocket(In the case of 65kg weight) Wheel...
  • Page 13 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.