TAKEGAWA CRF150F Hyper S-Stage CRF 150F Motorcycle Accessories Instruction Manual
Below you will find brief information for CRF150F Hyper S-Stage CRF 150F. This manual describes the installation process of the CRF150F Hyper S-Stage kit for the Honda CRF 150F motorcycle. It includes all necessary steps to install this kit, with detailed instructions on how to prepare the engine and install the new parts. It also addresses safety considerations and provides important information on carburetor settings and engine run-in.
Advertisement
Advertisement
Instruction Manual for CRF150F Hyper S-Stage Kit
Item No.
:01−05−0102
Applicable Model : Honda CRF 150F (Up to ‘05 models)
・Thank you for purchasing one of 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.
・This is a combined kit of a bore-up and carburetor kits.
Features
COPY
This product is so designed to achieve a higher compression ratio than stock engines. As for the fuel, high-octane gasoline should always be used.
In case regular gasoline is used, abnormal combusiton will take place, and the engine cannot achieve its original performance. Moreover, the piston likely will be damaged, leading to a serious failure of a motorcycle. Before installing this kit, make sure that no regular gasoline remains in the fuel tank. In case regular gasoline remains in the fuel tank, do replace it with high-octane gasoline.
!Safety information on spark plugs!
Be sure to replace a spark plug with a hot-type spark plug DPR9EA-9(NGK) or the one with a higher thermal value. Determine the heat value of a spark plug depending on how much it is burnt.
・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.
・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’.
・This kit is designed for exclusive use in the above-mentioned applicable model name. This kit cannot be mounted on other types of motorcycles.
・Installation of this kit requires engine removal. Please strictly follow HONDA’s genuine service manual for your vehicle to do the work correctly.
・Prepare right tools to do the work, strictly following the installation procedures with great caution. Besides, this instruction manual, as well as HONDA’s
genuine service manual, is prepared for those persons who have basic skills and knowledge. Therefore, we recommend those who are technichally
inexperienced or do not have sufficient tools to ask a technically-reliable specialist shop for the work.
・Never fail to do the shake-down.
・The installaiton of this product increases the heat release value of the engine, set off by the increase in power, which is unsuitable for long hours of
high-load driving.
・Some of bolts, nuts, dowel pins and packings will be reused. But always replace the severely worn or damaged parts with new ones.
・Carburetor setting needs to be changed according to the natural phenomena like the weather, temperatures, altitude and barometic pressure, and vehicle
model type and individual carburetor difference. Arrange the setting to match the engine and conditions.
The following show the envisioned possibility of injuries to human bodies or property damages as a result of disregarding the following
Caution cautions.
・Work only when the engine and the muffler are cool. (Otherwise, you will burn yourself.)
・Prepare right tools for the work. (Otherwise, parts will be damaged or you will suffer injuries.)
・Always use a torque wrench to screw bolts and nuts to the specified torque. (Improper torque could cause these parts to get damaged or fall off.)
・As some products and frames have sharp-pointed or protruding portions, please work with your hands protected.
(Otherwise, you will suffer injuries.)
・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.)
・Check gaskets and packings carefully for wear or damage. Always replace the worn or damaged parts with new ones.
Warning
The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the following cautions.
・Always start the engine in a well-ventilated place, and do not start it in an airtight place. (Otherwise, you will suffer from carbon monoxide
poisoning.)
・When you notice something abnormal with your motorcycle while riding down a road, immediately stop riding and park your motorcyle in a safe
place. (Otherwise, the abnormaility could lead to an accident.)
・Before doing the 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.)
・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 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 could lead to an accident.)
・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.)
・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. (It may cause a fire.)
◎ Please be informed that, because of improvement in performance, design changes, and cost increase, the product specifications and prices are
subject to change without prior notice.
◎ We shall be held harmless against any claim whatsoever arising out of use of the products in racing and the like.
◎ This manual should be retained for future reference.
- 1 -
1
6
10
12
2
7
11
5
13
15
∼ Kit Contents ∼
14
16
18
9
19
17
No.
Part Name
1 Piston φ67
2 Piston ring set
3 Piston pin φ15x48
4 Piston pin circlips φ15
5 Cylinder
6 Cylinder head gasket
7 Cylinder gasket
8 Cam sprocket cover gasket 1
9 Tensioner lifter gasket 1
10 Camshaft
11 Carburetor MIKUNI VM26
1
1
12 Throttle cable 849 mm
13 Carburetor insulator
14 Intake manifold
15 Intake manifold gasket
1
1
1
1
16 Clamp band 30-45 mm
17 Clamp band 32-50 mm
18 Socket cap screws 6x15
19 Throttle valve spring
1
1
4
1
2
1
1
1
Qty
1
1
1
Factory preset mode of the carburetor
Main jet
Pilot jet
Jet needle
Clip position
Throttle valve cut-away
Air screw opening
# 190
# 22.5
5E75
3rd from top
# 1.5
1-1/4 counterclockwise turns
∼ Installation Procedures ∼
◇ As the engine needs to be removed during the work, secure the vehicle on a stand on level safe ground. Do the following work only when the engine
and the muffler are cool.
◇ Turn off the fuel cock, and prepare an oil-receiving tray. Open the drain cock on the carburetor to drain gasoline in the float chamber.
●Removal of Engine and Other Parts
◇ Referring to Honda’s service manual, remove
or disconnect the following parts.
・Seat / left and right side cover
・Fuel tank / fuel hose
・Wires to the engine
・Spark plug cap
・Clutch cable
・Crankcase breather tube
・Drive sprocket
・Exhaust pipe
◇Take apart the throttle housing, and disconnect
the throttle pipe from the throttle housing to
detach throttle cables.
◇ Loosen a carburetor top and pull out a throttle
valve, and detach normal throttle cables from
the body. At this point, remember how the
stock throttle cables are routed.
◇ Unfasten bolts which are fixing an intake
manifold to the cylinder head. And loosen a clamp
which is connecting a carburetor and air
cleaner, and detach the intake manifold /
carburetor.
◇ Unscrew bolts / nuts which are mounting the
engine, and then demount the engine from the
frame. Be careful not to scratch the frame, etc.
●Removal of Spark Plug
◇ Remove a spark plug.
●Removal of Cam Sprocket
◇Remove tappet hole caps / O-rings and cam
sprocket cover / O-ring on both intake and
exhaust sides. Completely wipe off gaskets with
a scraper and the like, if any remains on the
cylinder head or cam sprocket cover.
Tappet hole cap
Cam sprocket cover
◇Remove a timing hole cap and crank shaft hole
cap.
Timing hole cap
Crank shaft hole cap
- 2 -
◇ Rotate the flywheel counterclockwise to be at ●Removal of Cylinder Head, Cylinder and ● Installation of Piston
TDC (Top Dead Center) on the compression
Piston.
◇ Attach a piston pin circlip to one of the two pin
stroke. This means that a “T" mark on the
◇ Loosen the nuts / washers and bolts on the
holes on the piston of the kit.
flywheel is aligned with an alignment mark on
cylinder head diagonally in a few steps, and
※ Arrange the position of the end-gap of the
the crankcase cover and that a rocker arm is
remove a cylinder head cover. Take off and check
piston pin circlip not to be on the notch of the
loose or shaky.)
two dowel pins, an oil hole plug and camshaft for
abnormality. If nothing wrong is found, reuse them.
COPY
Dowel Pins
piston pin hole.
Piston
Circlip
Notch end- gap
◇ Attach piston rings of the kit to the piston.
Fix both the top and second rings with “RN”-
stamped sides facing upwards.
※ Be careful not to scratch the piston or damage
piston rings.
Piston
Top ring
Second ring
Side rails
Expander
Pay attention to cross section as well.
◇Holding the flywheel, loosen a cam sprocket
bolt.
◇Remove the cam sprocket bolt, detach the cam
sprocket from the cam shaft, and detach the
cam sprocket from the cam chain.
◇ Remove a sealing screw / O-ring, and lock the
lifter on the cam chain tensioner. (The lifter will
lock if you turn the stopper all the way
clockwise.) Unscrew bolts and washers to
remove the cam chain tensioner from the
cylinder.
Oil hole plug
◇Unscrew bolts / washers, and detach a cam chain
tensioner slider from the cylinder head.
Tensioner slider
Bolt
◇ Apply engine oil to the piston pin of the kit, the
pin hole on the piston, and the small end of the
connecting rod. Then, attach the piston to the
connecting rod with a “ △ ” mark on the top
surface of the piston pointing to the exhaust
side, and attach a piston pin circlip of the kit.
◇ Apply engine oil to the piston rings and check
that each ring rotates smoothly. Do not align the
piston ring end gap with the piston pin or 90
degrees to the piston pin. Space the ring end
gaps 120 degrees apart.
(See the figure below.)
Mark
Sealing screw
Mark
Top ring
120°
120°
120°
Bolts
◇ Remove a cylinder head, and take off and check
two dowel pins and a cam chain guide for
abnormality. If nothing wrong is found, reuse them.
◇ Remove the cylinder, and take off and check two
dowel pins for abnormality. If nothing wrong is
found, reuse them.
◇ Detach a piston pin circlip and pull out the piston
pin to demount the piston.
※ Plug the opening on the crankcase with a waste
cloth not to get a circlip in it.
◇ Wipe off gaskets on the surface of the
crankcase to mate with a cylinder with a scraper
if any.
2nd ring
Expander
Pin direction
25mm 25mm
Side rails
90°to the pin
Piston
- 3 -
Oil hole plug
Dowel pins
◇ Loosely tighten 4 washers / nuts and 5 bolts. ◇Attach a timing hole cap and a crank shaft hole ●Installation of Cylinder
Tighten up nuts first diagonally in a few steps.
cap.
◇ Remove the plugged waste cloth.
Specified torque:
for cylinder head nut:
Specified torque:
for timing hole cap:
◇ Look into a cam chain hole and check that the
cam chain has not come off the sprocket on the
27 N・m (2.8 kgf・m) 10 N・m (1.0 kgf・m) crank shaft.
◇ Degrease the mating surfaces of the for cylinder head bolt: for crankshaft hole cap:
crankcase and cylinder with thinner and the
like, and attach a dowel pin and cylinder gasket
of the kit.
◇ First clean the inside of the cylinder by
degreasing it with thinner, and apply engine oil
and spread the oil evenly with your fingers.
◇ Fit the cylinder into the piston little by little with
fingers, being careful not to move the piston
ring end gaps out of place. And place the
cylinder in the crankcase.
※ After the cylinder has been placed inside the
12 N・m (1.2 kgf・m)
●Installation of Cam Sprocket
◇ Check that a “T” mark on the flywheel is aligned
with an alignment mark on the crankcase cover.
◇Fix the cam sprocket to the cam chain, aligning an
COPY
Specified torque: 12 N・m (1.2 kgf・m)
8 N・m (0.8 kgf・m)
◇ Attach an O-ring and a gasket of the kit to the
cam sprocket cover, and fix them to a cylinder
head with two bolts.
Specified torque:
9 N・m (0.9 kgf・m)
◇ Fix the tappet hole cap / O-ring on both intake
and exhaust sides to the cylinder head.
Specified torque:
15 N・m (1.5 kgf・m)
●Installation of Spark Plug
◇ Prepare a spark plug and fix it.
Specified torque:
18 N・m (1.8 kgf・m)
※ Replace a spark plug with a hot-type spark
piston, pass the cam chain through the
cylinder.
◇Degrease the upper part of the cylinder, and fix
the cam chain guide, two dowel pins, and a
cylinder head gasket of the kit. Fit the cam chain
guide right into the grooves in the cylinder and
the crankcase.
plug DPR9EA-9(NGK) or the one with a higher
thermal value.
Gasket
Guide
●Installation of Cylinder Head
◇Degrease the mating surface of the cylinder
with thinner. Pass the cam chain through the
cylinder head, and then fix the cylinder head.
◇ Fix the cam chain tensioner slider to the
cylinder head with bolts / washers.
◇ Attach the cam shaft of the kit, two dowel pins
and an oil hole plug, apply liquid gasket to the
clamp face for a cylinder head cover, and
install it with a cam top of cam shaft pointing
towards the combustion chamber.
Dowel pins
◇Make sure that a cam chain tensioner's lifter is
locked. Attach a gasket of the kit to the cam chain
tensioner, and install it to the cylinder with two
bolts / washers. Unlock the lifter by turning a cam
chain tensioner's stopper counterclockwise.
Attach a cam chain tensioner's sealing screw /
O-ring.
Specified torque:
for tensioner fixing bolt:
12 N・m (1.2 kgf・m)
for ceiling screw:
4 N・m (0.4 kgf・m)
Sealing screw
●Installation of Engine and Other Parts
◇With reference to HONDA’s genuine service
manual, place the engine in the frame with care
not to scratch the frame or other parts. Then
temporarily tighten mounting bolts / nuts. Insert
a drive sprocket, already attached with a drive
chain, into the counter shaft. If it is hard to do
so, insert it while shaking the engine lightly.
◇With moderate slack on the drive chain, fully
tighten the temporarily-tightened mounting bolts
/ nuts. And fix the drive sprocket.
◇ Referring to Honda’s genuine service manual,
reinstall or connect the removed or
disconnected parts.
・Wires to the engine
・Spark plug cap
・Clutch cables
・Crankcase breather tube
・Seat / left and right side covers
・Fuel tank / fuel hose
Bolt
◇Rotate the crank shaft clockwise, and align again
the "T" mark on the flywheel with the alignment
mark on the crankcase cover. At this point, check
that the "I" mark on the cam sprocket is still aligned
with the mating surface of the cylinder head.
●Installation of Carburetor
◇Connect the throttle cables of the kit to the
throttle housing / throttle pipe, and fix them to a
handle. Route the throttle cables just like the
stock throttle cables are routed.
Liquid gasket application
- 4 -
Notch
throttle spring.
◇Fix the intake manifold of the kit and intake ◇Adjust the free play at the throttle grip to be about ●Starting of Engine
manifold gasket with two socket cap screws 5 mm by turning the adjuster of the throttle cable.
1.About fuel
attached to a cylinder head. Beware of the After the adjustment, cover the adjuster with a
◇ Always use high-octane gasoline.
directional properties of the intake manifold and rubber adjuster cover.
◇ Whenever regular gasoline is remaining in the
gasket.
fuel tank, always replace it with high-octane Adjuster
and throttle valve.
Specified torque:
10 N・m (1.0 kgf・m)
Less free play more free play
About 5 mm
COPY gasoline
2.Checking of Every Section
◇ Check every section for slack in screws, nuts,
etc.
◇ Pull the choke lever to start the engine with
utmost care in a well-ventilated safe place.
Gradually push the lever back and warm-up
the engine till it starts running smoothly, and
then push back the choke lever to the end. Keep
the vehicle running idle for a few minutes till the
engine oil circulates evenly all around the
engine. Adjust revolutions with the throttle stop
screw in case the engine does not run idle or
runs idle at high revolutions.
◇ Check for any abnormality such as abnormal
sounds from the engine, oil leak from gaskets,
and exhaust-air leak from a joint on an exhaust
◇ Fix the insulator of the kit with two socket cap
screws attached to the intake manifold.
Specified torque:
10 N・m (1.0 kgf・m)
◇ Detach a top cover from the carburetor of the
kit, and take out a spring, needle clip retainer,
throttle moves smoothly without sticking and that
the valve is fully open.
※ Also check that the throttle has free play even
when the steering handle is turned all the way to
the right and left.
◇Remove a restrictor at the top of an air-cleaner
box. If it is left attached, the big carburetor does
pipe.
not display its ability to the full.
◇Fix the top cover to the throttle cables. With the ◇ Stop the engine, and after the engine has
become cool enough, check every section again spring pressed, attach the throttle valve to the
for slack in screws, nuts, etc.
inner cables, and then the needle clip retainer.
◇Do the settings, in a safe place with caution, to ※Be sure to change the spring to the supplied
meet your requirements.
◇Aligning the notch in the throttle valve with a
throttle stop screw, fit the throttle valve into the
carburetor.
3.About running-in
◇ For the purpose of shakedown of the piston
and cylinder, never fail to run in the vehicle for
about 100 km at the reduced engine
revolutions, avoiding the sudden acceleration.
● Installation of Exhaust Pipe
◇ Referring to Honda’s genuine service manual, fix
an exhaust pipe.
Throttle stop screw
◇ First, fix the air-cleaner box portion of the
carburetor, and fasten it with a hose clamp
(32-50 mm).
※ Generally, it is hard to fit the throttle valve into
the carburetor. In case you cannot easily fit it,
fit it using a flat tip screwdriver.
And, fasten the clamp in the position as close
to the carburetor as possible.
◇Then, fit the carburetor into an insulator, and
fasten it with a hose clamp (30-45 mm).
3-5-16 Nishikiorihigashi Tondabayashi
Osaka Japan
TEL : 81-721-25-1357
FAX : 81-721-24-5059
URL : http://www.takegawa.co.jp
- 5 -
Please be informed as follows with regard to the supplied MIKUNI VM26 Carburetor:
A standard on-road throttle valve spring is incorporated into this VM26 carburetor at
In connecting the throttle wires, please be sure to replace the spring with the sup-
This hard throttle valve spring serves to ease the malfunction triggered by the throttle closure caused by the mud and sand adhering to the throttle, throttle wires, throttle
However, please note that this does not go so far as to completely prevent the poor return of the throttle caused by dirt. Therefore, before riding, inspect various parts,
COPY
Please be informed as follows with regard to the supplied MIKUNI VM26 Carburetor:
Warning
A standard on-road throttle valve spring is incorporated into this VM26 carburetor at the factory.
In connecting the throttle wires, please be sure to replace the spring with the supplied off-road heavy-duty throttle valve spring.
This hard throttle valve spring serves to ease the malfunction triggered by the throttle closure caused by the mud and sand adhering to the throttle, throttle wires, throttle valve and other hardware.
However, please note that this does not go so far as to completely prevent the poor return of the throttle caused by dirt. Therefore, before riding, inspect various parts, and stop riding whenever you feel something abnormal when driving.
Warning
Please be informed as follows with regard to the supplied MIKUNI VM26 Carburetor:
A standard on-road throttle valve spring is incorporated into this VM26 carburetor at the factory.
In connecting the throttle wires, please be sure to replace the spring with the supplied off-road heavy-duty throttle valve spring.
This hard throttle valve spring serves to ease the malfunction triggered by the throttle closure caused by the mud and sand adhering to the throttle, throttle wires, throttle valve and other hardware.
However, please note that this does not go so far as to completely prevent the poor return of the throttle caused by dirt. Therefore, before riding, inspect various parts, and stop riding whenever you feel something abnormal when driving.
and stop riding whenever you feel something abnormal when driving.
and stop riding whenever you feel something abnormal when driving.
return of the throttle caused by dirt. Therefore, before riding, inspect various parts,
However, please note that this does not go so far as to completely prevent the poor valve and other hardware.
valve and other hardware.
closure caused by the mud and sand adhering to the throttle, throttle wires, throttle
This hard throttle valve spring serves to ease the malfunction triggered by the throttle plied off-road heavy-duty throttle valve spring.
plied off-road heavy-duty throttle valve spring.
In connecting the throttle wires, please be sure to replace the spring with the supthe factory.
the factory.
A standard on-road throttle valve spring is incorporated into this VM26 carburetor at
Please be informed as follows with regard to the supplied MIKUNI VM26 Carburetor:
Warning Warning
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:
・The explosion sound with a dull thud continues intermittently.
・The engine malfunctions further if you use the choke.
・The engine malfunctions when you warm it up.
・The engine works well if the cleaner is detached.
・The motorcycle belches dense (or, black) exhaust gas.
・The plug smolders, getting blackened.
When the air-fuel mixture is too lean:
・The engine overheats somewhat.
・The engine starts working well If you use the choke,.
・The engine does not accelerate well. (No smooth acceleration)
・Revolutions change, generating weak power.
・The plug burns white.
Whether or not the engine revolution is in proportion to the throttle operation
・When the acceleration is not smooth or even, make the air-fuel mixture dense.
・Make the air-fuel mixture lean when the engine revolution goes up heavily and belches black gas.
The mixture ratio at this throttle position can be adjusted by the location of E-ring in the grooves. The air-fuel mixture becomes dense as the
location of the E-ring moves down from the 1st to the 5th groove.
○Main jet (The throttle position at 3/4 - 4/4)
The air-fuel mixture ratio at this throttle position can be adjusted by changing the number of the main jet. The larger the main jet numbers, the
denser the mixture ratio becomes.
In view of the engine and muffler specifications, select the most appropriate main jet to get the highest revolutions.
○Pilot jet (First of all, please adjust the air screw.)
・In case you have given more than three turns to the air screw to tighten it, use a pilot jet with a small number.
・ If you have tighten the air screw (clockwise) to the full, use a pilot jet with a larger number.
Check whether you have made a right choice of the pilot jet by seeing if the engine starts up revolving smoothly from the idling to running
at slow speed.
・When the engine revolves up unevenly, the pilot jet number is too small. (At idle)
・ When the motorcycle belches black exhaust gas and produces heavy exhaust sound, the pilot jet number is too big. (At idle)
・After replacing the pilot jet, you need to readjust the airscrew.
○ Air screw
The air screw adjusts the air mass flow at the time of engine’s revolving at slow speed. (At idling)
・Give the air screw a right turn → The air-fuel mixture gets dense.
・Give the air screw a left turn → The air-fuel mixture gets lean.
Loosen the tightened air screw back to the 1.5-turn position. And then from this position, give to the airscrew a right or left turn of 1/4 to 1/2
till the engine revolves at the highest speed.
Loosen the idle stop screw till you get the steady idling revolutions. And once again adjust the position of the airscrew to get the highest
revolutions.
●On how the barometric pressure, temperatures and humidity affect the setting:
・At highlands or at high altitudes, the barometric pressure and air density go down and the air gets into the carburetor in less amounts.
This makes the air-fuel mixture dense which was adjusted at low altitudes.
・Under the weather conditions with very low temperatures, the air density increases, which makes the air-fuel mixture lean.
・Under the rainy and humid weather conditions, the air density decreases, which makes the air-fuel mixture dense.
◎ 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.
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

Public link updated
The public link to your chat has been updated.
Advertisement
Key features
- Bore-up and carburetor kit
- Increased displacement
- High-octane gasoline required
- Hot-type spark plug required
- Engine removal required
- Detailed installation procedures
- Carburetor setting instructions
- Engine run-in instructions
- Safety precautions