Instruction Manual for 80cc S

Item No.：０１ - ０５ - ５０８３

Applicable Models

Instruction Manual for

Frame Nos

：AC16-1000001 ∼

Ape

80cc S-Stage Bore Up Kit

！ Caution about fuel to use！

regular gasoline is remaining in the fuel tank, do replace it with high-octane gasoline.

CB50J

CB50SA

◎ Please note that, in some cases, the illustrations and photos may vary from the actual hardware.

：CB50J-1000011 ∼ 1127783

：AC02-1000007 ∼ 1016876

：AC02-1100006 ∼ 1107894

：HD14-1000001 ∼

Thank you for purchasing 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.

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 takes place, and the engine cannot achieve its original performance. Moreover, it is highly likely that the piston will break down, leading to serious failure of the vehicle. Before installing, make sure that no regular gasoline remains in the fuel tank. In case

！Caution about spark plug！

Be sure to replace a spark plug with high thermal value of CR8HSA (NGK) or U24FSR-U(DENSO). Subsequently, choose and use a right spark plug with the right level, depending on the degree of burning of the spark plug electrode section.

！ Caution about sprocket！

CB50SB

XR Motard

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, please replace the drive and driven sprockets to make the gear ratio high.

(Camshaft-less)

COPY

Please read the following instructions before installation.

◎The following show the envisioned possibility of injuries to human bodies, and physical loss or damage as a result of disregarding the following cautions.

◎ 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 alterations to the products, we shall be held free from any guarantee of them.

◎ 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 types of motorcycles and frame numbers only. Please take note that this product cannot be

mounted on other types of motorcycles.

◎Installation of this kit requires engine removal and mounting. We strongly recommend you to work strictly following HONDA genuine parts service manual

for your vehicle.

◎ For installation, please prepare tools (as specified on page 2 ) and work with reference to the installation procedures with enough care. Besides, this

instruction manual, as well as HONDA’s genuine parts service manual, is prepared for persons who have acquired basic skills and knowledge in tuning.

We recommend those who are technically inexperienced or without enough tools to ask a technically-reliable specialist shop for the installation work.

◎ On the Ape（Carburetor） or XR50 Motard, this Kit alone does not perform well. Please separately purchase a Carburetor Kit.

PC20 Carburetor Kit: 03-05-317, 03-05-318, coming with a filter

◎ Installation of this Kit alone does not ensure the highest performance of the fuel-injection-system (FI) Ape. You are required to additionally purchase

an FI controller available as an optional extra.

FI Controller : 03-05-0014

◎ We would recommend our TAKEGAWA’s muffler to make your engine more powerful.

◎ In some cases, the setting needs to be redone when this kit is installed onto CB50 and its exhaust muffler has been changed.

◎ Some of bolts, nuts, dowel pins and packing 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 break the engine.

◎ Installation of this product requires left side crankcase cover gaskets (HONDA’s item No. 11394-KN4-750), which please purchase.

CAUTION

The following show the envisioned possibility of injuries to human bodies and property loss as a result of disregarding the following cautions.

･Work only when the engine and the muffler are cool. (Otherwise, you will burn yourself.)

･Prepare right tools for the work, and do the work in the proper and right way.

(Otherwise, improper work could cause breakage of parts or injuries to yourself.)

･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.)

･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 carefully gaskets and packings, and in case wear or damage is detected, always replace them with new ones.

WARNINGS

The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the following cautions.

･Please always try to ride a motorcycle at legal speed on the public road, abiding by the law.

･Always drive the engine in a well-ventilated place, and do not switch the engine on 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, stop riding immediately and park your motorcyle in a safe place.

(Otherwise, the abnormaility could lead to an accident.)

･Before doing work, place the motorcycle on level ground to stablize the position of your motorcycle for safety's sake.

(Otherwise, your motorcycle could fall down 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 maintence could lead to an accident.)

･If you find damaged parts when checking and performing maintenance, 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 an accident.)

- 1 -

◎ 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.

１

About Screws

◇ Usually, counterclockwise rotation loosens the bolts and nuts, and clockwise rotation tightens them.

◇ When tightening a screw, at first tighten it by hand at tight as you can.

◇ To loosen a screw means turning a tightened screw around three or four times counterclockwise, and to unscrew it means turning it around

counterclockwise until it comes off.

◇ To tighten a screw means to keep a screw from getting loose. The numeric valve as a guide at which a screw will not break or get loose when tightened

COPY

◇ Improper use of tools will result in breakage of the top of a bolt or screw.

∼ Kit Contents ∼

２

８

６

７

９

１０

Ｂ

Ａ

01-13-021 : Gasket set

３４

５

８

２―Ａ

６

７

No.

1 Piston

Parts Name Qty Repair Part Item No.

in packs of

1 13104-149-T00 1

2 Cylinder assembly.

1 01-01-041

2-A Aluminum Sealing Washer 2 09-071-015

1

10

2-B Oil Plug Bolt

3 Piston ring set

4 Piston pin

2

1

1

000-13-020

13011-GBG-T00

13112-165-T01

1

1

1

5

6

7

8

9

Piston pin circlip

Cylinder head gasket

Cylinder gasket

Exhaust pipe gasket

Inlet pipe gasket

10 Mark set

2

1

1

1

1

1

000-02-120

12251-GEY-T00

000-13-062

000-13-058

000-13-066

2

2

6

1

4

∴ Please order repair parts by indicating the Repair Part Item No. as listed above. As you see from the list, there are some parts for which we are not

in a position to accept your order in the quantity of one. In this case, please order the required parts as a set part unit.

- 2 -

∼ Installation Procedures ∼

In the case of the FI Ape:

●Engine Removal

XR50 Motard

the connector. And pull out the connector.

◇Unfasten the flange bolts on the right and left side

◇After turning off the main switch, disconnect a black

Seat and Tank Removal

Lock tab

Retainer tab

2P coupler from the fuel pump unit.

covers to remove the right and left side covers.

In the case of a carburetor Ape:

2P coupler

Connector

◇After turning on the main switch, crank the engine

more than five times with a kick starter in order to

depressurize the inside of the fuel hose.

◇Turn off the main switch.

In the case of a carburetor Ape,

CB 50 & XR Motard:

◇Unscrew two bolts, and remove the seat by pulling it

toward the back of the vehicle.

Hook

Fuel tank

Seat

◇Shut off the fuel petcock.

COPY

Bolts

◇Unscrew a bolt and remove the fuel tank by pulling it

toward the back of the vehicle.

Bolt

Collar

Fuel tank

Joint rubber

to prevent the dust and dirt from getting into the

connector.

◇Following the above example, detach the quick

connector on the side of the throttle body.

◇Unfastening a mount bolt and a collar, and two pieces

each of bolts and collars, demount the tank.

Mount bolt

Collar

Removal of Carburetor

(Throttle body)

In the case of the carburetor Ape,

CB 50, and XR Motard:

◇Remove a carburetor’s top cap, and pull out the

throttle valve from the carburetor.

Collar

Bolt

Fuel pump unit & cover

◇Stabilize the body firmly with a racing stand or the

like in order to remove the side stand.

※On CB50, you cannot use the racing stand without

detaching a stock muffler.

First, secure your motorcycle firmly on a side stand,

and then detach the muffler referring to “Exhaust

Muffler Removal”.

※Work only when the engine and the muffler are

cool.

※Take off all dirt like the dust and oil on each part as

you detach it.

※Don’t let the removed bolts and nuts go astray, and

keep them orderly so you can recall where to fix

them.

◇Shift the tube clip to disconnect the fuel tube.


◇Unfasten two bolts and collars to demount the seat.

Seat

Hook

Side Cover Removal

◇Unscrew a bolt on the right side cover.

The cover can be removed by detaching two bosses

from the frame.

Right side cover

Bosses

◇Loosen a screw on the connecting tube band.

◇Unscrew two bolts, and remove a manifold and the

carburetor from the cylinder head.

Bolts & Collars

※ How to remove the quick connector:

Bolt

◇Dismount three bosses on the left side cover from

the frame, then the side cover becomes detached.

Bosses

(-) Cable

Battery

Rubber band

(+) Cable

an air-blower, and cover the portion with a waste cloth.

On the side of the throttle body

On the side of the fuel pump unit

Left side cover

CB50

◇Unfasten and remove three bosses on the right and

left sides.


◇Unfasten the screw to remove the throttle drum

cover.

Screw

Cover

Quick connector

- 3 -

◇Disconnect a black 4P coupler from IAC valve and

a black 2P coupler from the injector.

4P coupler 2P coupler

XR50 Motard

◇Detach two flange bolts to remove the exhaust muffler.

Wiring Disconnection

In the case of carburetor Ape:

◇Disconnect the wiring.

◇Loosen the nut on a clutch cable guide, and

disconnect a clutch cable from a lifter lever.

◇Disconnect a black 5P coupler from the sensor

unit.

◇Disconnect the clutch cable from the cable guide.

5P coupler

◇Loosen the lock nut to remove the throttle cable

from the cable holder and throttle drum.

Holder

Cable

Lock nut

Drum

◇Loosen the connecting tube band screw and

insulator band screw to remove the throttle body.

Band screws

◇Unfasten a lock nut and washer to remove the exhaust

muffler.

Sensor Coupler Removal


◇Disconnect a brown 2P coupler from the oil

temperature sensor and a black 2P coupler from the 02

sensor in order to remove 02 sensor cord from the

clamp.

02 Sensor 2P Coupler

◇Remove a screw on the tachometer cable to

remove the cable. (In the case of CB 50)

※Pull out an exhaust pipe from between a step and

engine.

Sensor cord & clamp

Throttle body

※After removing the throttle cable from the throttle

body, never snap the throttle valve from the full-bore

to the fully-closed position.

※Never hit the throttle body hard like dropping it.

Otherwise, the severe shock may cause the throttle

body to malfunction.

Exhaust Muffler Removal

◇Take off two nuts on the cylinder head side.

Spark Plug Removal

◇Pull a plug cap to demount it. Be sure to pull the cap,

not a wire.

2P coupler from the oil temperature sensor

◇Unfasten a wire band, and disconnect a green 2P

coupler from the side stand switch and a brown 5P

coupler from the AC generator.

2P Coupler

Drive Sprocket Removal

◇Unscrew five bolts on the left side crankcase cover,

and remove the left side crankcase cover.

5P Coupler Wire band

◇Disconnect the wiring of the breather hose.

(in the case of Ape)

◇If the gasket material remains on the mating

surfaces, get rid of it with a cutter or a scraper.

◇Remove a spacer in advance.

◇Remove a spark plug.

Ape

◇Unscrew and remove mounting bolts and

washers, and detach an exhaust muffler.

Spacer

- 4 -

◇Unscrew two bolts on the drive sprocket, and

remove a fixing plate and the drive sprocket.

◇Remove a nut on the upper rear engine mount.

◇Fix a flywheel, and loosen two hex’ bolts on a cam

sprocket.

◇Loosen an adjust bolt and lock nut at the back of the

cylinder.

Lock nut

COPY

◇Remove the side stand switch cord from the frame.

Left Step Removal

in the case of Ape

◇Remove a bottom side nut also.

◇First, pull out the upper side bolt and then remove a

collar (Ape) and the clutch cable guide.

◇Unfasten a lock bolt and a set plate, and remove an

adjuster.

Set plate

Lock bolt

◇Demount a cylinder head mounting bolt.

◇After loosening 4 camshaft holder nuts diagonally

in a few steps, detach 4 washers, a camshaft holder,

a camshaft, a bush (FI Ape) and a dowel pin.

Adjust bolt

◇Remove two hex’ bolts from the cam sprocket.

◇Unscrew two bolts, and remove the left step.

Engine Removal

◇Place a jack or substitute stand under the engine

to hold up the engine.

◇Take out the bolt on the lowr side, and detach the

engine from the left side of the frame. Be careful not to

give scratches to the frame.

◇Detach the cam sprocket from the cam shaft and then,

from the cam chain.

◇Detach four nuts on a front engine hanger, take

four bolts out, and remove the front engine hanger.

●Removal of Cylinder Head,

Cylinder, and Piston

Cylinder Head Removal

◇Unscrew two bolts on the cylinder head cover, and

remove the cylinder head cover and its gasket.

◇Suspend the cam chain with a wire or the like to keep

it from falling into the case.

- 5 -

Cam chain guide

◇Remove the cylinder head.

◇Remove a lock nut and an adjust bolt from the cylinder.

● Crankcase Modification

◇Push out the piston pin with a driver or the like in the

direction where one of the two circlips has just been

removed.

※In fixing the cylinder onto the crankcase, in some

cases a cylinder sleeve and a crankcase sleeve

hole may interfere with each other, due to right and

left crankcases being out of alignment and for other

reasons. Since the use of these parts as they are

will lead to sleeve deformation and engine troubles,

for re-use.

◇Detach two dowel pins in advance and keep them

COPY

◇With a cutter or a scraper, get rid of the gasket

scraps remaining on the cylinder head plane on

which to fit a manifold.

◇Detach a spring, and remove a cam chain tensioner

from the cylinder.

◇Now you can take out the piston.

do not fail to check these parts for the interference.

Interference part

◇Plug the hole in the crankcase with a waste cloth

not to let cutting chips get into the case.

◇Scrape the convex parts on both right and left

crankcases till the mating surfaces become level.

◇After scraping, remove the cloth with enough care

not to let any chip get into the case.

Left side crankcase

Right side crankcase

Cylinder sleeve

Mating Surface Cleaning

◇Completely get rid of the gasket scraps on the mating

surface with a cutter or a scraper.

Be careful not to give scratches to the surface.

After scraping

◇Stuff up the sleeve hole with some clean cloths.

◇After installation of the kit, idle away the engine for

a few minutes, and replace the engine oil with the

new one without delay.

Cylinder Removal

◇Remove the cam chain guide, and pull out the

cylinder. (If it is hard to pull it out, hit the cylinder

lightly with a plastic hammer.)

◇Plug the cylinder hole on the crankcase and a cam

chain hole with a waste cloth or clean rag not to let any

dirt or part fall into the hose.

◇Wipe the surface with a waste cloth.

◇Take off two dowel pins in advance and keep them

for reuse.

Piston Removal

◇Remove one of the two piston pin circlips.

※You can remove it by prising it open with a screwdriver

with its tip on the notch.

- 6 -

◇Fix the oil ring expander.

●S-Stage Kit Installation

Piston Installation

◇Fix the second ring, turning up the side with an

engraved letter “N”.

◇Attach two dowel pins and a cylinder gasket to the

crankcase.

Cylinder Installation

◇Insert the cam chain tensionner into kit’s cylinder, and

hang the hook of the spring on the cylinder.

◇Fix one of kit’s piston pin circlips to a pin hole.

※Place a circlip so its end gap does not meet with

120°

the notch on the pin hole.

Gasket

the piston with a screwdriver, but taking care not to

damage the piston with a screwdriver.

※Do the job carefully as, in some cases, the circlip

comes off flying while you press it inside.

※You can rather easily install it by pressing it into

COPY

◇Fix piston rings according to the figure below.

120°

◇Fix the top ring, turning up the side with an engraved

letter “N”.

◇Apply engine oil to the piston pin hole.

◇Place the cam chain tensioner in a position so the end

of the rod will be nearly on the same level as the clamp

face.

Fix it with an adjust bolt and tighten the lock nut.

◇Apply engine oil to the inside of the cylinder and

spread it with fingers to be equally applied all over.

◇Apply engine oil to whole surface of the piston, and

the piston rings.

Dowel pins

120°

Rod’s end

◇Apply engine oil to a piston pin hole in the con’rod.

60° 60°

◇Let the cylinder in.

◇Apply engine oil to the piston pin and place the piston

in a position so the “EX” mark on the upper side of the

piston faces the front or exhaust side.

◇Remove the waste cloth.

◇Insert the piston into the cylinder gradually by hand

with care not to shift the piston ring’s end gaps out

of the position.

◇Fix the lower oil ring side rail.

◇Degrease the mating surfaces of the crankcase

and the cylinder with thinner or the like.

◇Fix the upper oil ring side rail.

◇When the piston is completely in the cylinder, pass

the cam chain through the cylinder and install the

cylinder to the crankcase.

◇Fix the other piston pin circlip, included in the kit, to the

pin hole.

※Place the circlip in a position so the end-gaps of a

piston pin circlip do not meet with the notch on the hole.

※It is relatively easier to press it by a driver with care not

to give scratches to the piston.

※Do the job carefully as, in some cases, thepiston pin

circlip may come off flying while you press it inside.

- 7 -

◇Insert the cylinder, fitting the end of a cam chain

guide into grooves in the crankcase and the

protrusion into grooves in the cylinder.

Protrusion

◇Install an adjuster, passing it through the cam chain

tensioner and the cylinder head.

◇Install the cam shaft holder.

◇Rotate the flywheel a little, and then rotate the cam

sprocket to mark it easy to install hex’ bolts.

◇Align cam shaft’s bolt-holes with the cam sprocket.

Then attach two hex’ bolts to the holes by hand

temporarily. At this point, attach and tighten a dowel

bolt (black) to the intake side.

※There is no distinction between left and right bolts

when installing onto the FI Ape.

guide シリンダー

Cylinder

◇Temporarily attach a set plate with a lock bolt.

◇Fix four washers.

Top end

COPY

◇Temporarily tighten the cylinder head mountiong

bolts.

◇Install and diagonally tighten four nuts equally in a few

steps.

Torque: 20N・m (2.0 kgf・m)

CB50

Torque: 12N・m (1.2 kgf・m) ◇Fix the flywheel and fully tighten the hex’ bolts on

the cam sprocket.

Cylinder Head Installation

“O” mark

Black bolt

Torque: 12 N・m (1.2 kgf・m)

◇Degrease the mating surfaces of the cylinder and

Ape FI

the cylinder head with thinner or the like.


Installation of Cam Shaft and

Cam Sprocket

◇Apply engine oil to the journal and cam surfaces of the

cam shaft, and install the camshaft to the cylinder head

with the camshaft’s cam top facing downwards

◇Fully tighten the cylinder head mounting bolts.


Cam

◇Attach two dowel pins and a cylinder head gasket

to the cylinder.

Dowel pins

Journal

◇If you are installing this Kit onto an FI Ape, please

install the Kit referring to the picture below.

Bush

◇Check that “T” mark on the flywheel is aligned with the

“▽” mark on the crankcase.

Cam Chain Adjustment

※A camchain, whether tightly or loosely streteched,

will impair the engine conditions. Perform this

procedure correctly.

◇Rotate the flywheel till both cam tops of the cam

shaft point up.

Cam tops should point this way.

Join together

Cam shaft ◇Rotate the flywheel a little by hand. Depending on

how tensely or loosely the camchain is stretched to

the camsprocket, turn the flywheel in either

direction to get the proper tension of the camchain,

watching the “O” mark on the adjuster.

Cylinder head gasket

◇Pass the cam chain through the cylinder head and

install the cylinder head to the cylinder.

Protrusion

◇Attach two dowel pins.

Dowel pins

◇Install the cam chain in the position so the “O” mark on

the cam sprocket is right at the top. Fit the cam sprocket

into the cam shaft.

Adjuster

Lock bolt

- 8 -

◇Temporarily tighten the two nuts.

Installation of Left Side

Crankcase

◇Tighten the lock bolt fully when the cam chain is

found stretched properly and you can move the

flywheel without difficulty, and fix the adjuster.


◇After tightening the nut, double check the valve

clearance with the 0.1mm thickness gauge.

◇Pour fresh engine oil to a oil pool on the cylinder

head to the brim.

◇Degrease the clamp faces of the left side

crankcase cover and the crankcase with thinner or

the like.

◇Attach a spacer, and install the left crankcase cover

and a new gasket to the crankcase by tightening

◇In case you can not get the proper tension of the

camchain only by adjusting the adjuster, then

adjust the tension with the adjust bolt on the

cylinder.

adjust bolt a little bit.

◇Install the cylinder head cover and its gasket to the

cylinder head by tightening two cylinder head cover

COPY

from the left side and temporarily tighten four nuts.

five bolts.


Spacer

◇Fix the adjust bolt with a flat tip screwdriver, and

tighten the lock nut.


◇Again, move the adjuster and hold it where the

camchain has no slackness and you do not feel it

hard to rotate the flywheel. Then tighten the lock

bolt to fix the adjuster.

●Engine Mounting

Engine Mounting

◇Place a jack or a proper stand under the engine to

support the engine. Then mount the engine from the

left side of the vehicle.

◇Insert a bolt into the lower part of the rear engine

mount from the left side.

(In the case of CB50, insert the bolt from the right

side.)

◇Fix the drive sprocket with the drive chain to the

counter shaft.

If it is hard to fix the drive sprocket, fix it while shaking

the engine lightly.

Installation of Left Side Step

in the case of Ape:

◇Install the left side step to the frame with two bolts.


Valve Clearance Adjustment

◇Rotate the flywheel counterclockwise, and stop

rotating it where the “O” mark on the cam sprocket

is on the top and the “T” mark on the flywheel is

aligned with the “▽” mark on the crankcase.

◇Insert a 0.1mm thickness gauge between the

adjust screw and the end face of the valve

(or, valve clearance).

◇Join a collar (in the case of the Ape) and a clutch cable

guide together, and insert a bolt into the upper part of

the rear engine mount from the left side.

◇Stretching the drive chain moderately loosely, fully

tighten the two nuts on the rear engine mount and the

four nuts on the front engine hanger plate.

Torque:

for rear engine mount nuts

: 44 N・m (4.5 kgf・m)

for front engine hangar plate nut

: 26 N・m (2.7 kgf・m)

◇Fit the fixing plate into the counter shaft to align with

the threaded holes on the drive sprocket, and fix two

bolts.


◇Fix the side stand switch cord on the clamp of the

frame.

◇Adjust the position of the adjust screw so that

there is a little resistance to pulling the gauge out.

Then tighten the nut.


Wiring



◇Connect the wiring.

- 9 -

◇Fix the cords with a wire band.

CB50

◇Install a washer, muffler bracket and washer, in this

order, to the pivot bolt, and loosely tighten the lock nut

for now.

◇Connect a black 5P coupler from the sensor unit.

Spark Plug Installation

◇At first, screw the spark plug by hand.

◇Then tighten it with a plug wrench.


Wire band

In the case of FI Ape:

◇Connect a green 2P coupler from side stand switch

and a brown 5P coupler from AC generator, and

fasten them onto the frame with a wire band.

5P coupler

◇Connect the breather hose.

(in the case of Ape)

2P coupler

◇Firmly tighten the loosely-tightened three parts.

COPY


C a r b u r e t o r ( t h r o t t l e body)Installation

Ape (carburetor), XR50

※This kit will not display its potential high performance

when used with a stock carburetor. Please purchase

◇Install a throttle drum cover and tighten the screw

to the specified torque.

Torque: 1.2 N・m (0.1 kgf・m)

Wire band

Screws

5P coupler

◇Connect a black 4P coupler from IAC valve and a

black 2P coupler from the injector.

4P coupler 2P coupler

separately a Carburetor Kit.

※For the installation, please refer to the Instruction

Manual of the Carburetor Kit.

Exhaust Muffler Installation

◇Temporarily tighten two nuts on the cylinder head side.

◇Attach the clutch cable to the lifter lever and install

it to the clutch cable guide. Then tighten the nut.

※A stock muffler on CB50 cannot be installed when the

motorcycle is secured on a racing stand. Install the

muffler only after securing the motorcycle on a side

stand.

※Insert the stock muffler from between the step and

engine.


◇Aligning the protrusion with the grooves, install the

throttle body onto the insulator. Tighten up the band

screw until the distance between the edges of the

insulator band comes down to 7 mm ± 1 mm, or 8 mm

to 6 mm.

7 mm ± 1 mm, or 8 mm to 6

Cover

CB50

◇Insert the carburetor into the connecting tube, and

fix the manifold to the cylinder head with two bolts.


Ape

◇Temporarily tighten two mounting bolts and washers.

◇Install the connecting tube onto the throttle body, and

tighten up the band screw firmly.

Band screws

◇Tighten the screw on the connecting tube band.

Join together

◇Mesh the notch on the cable inner with the

tachometer gear, insert the cable inner into the

tachometer gear, and secure the tachometer cable

with a screw. (CB50)

◇Here, tighten firmly three loosely-tightened parts.

Torque:

for two nuts: 12 N・m (1.2 kgf・m)

for mounting bolts: 13 N・m (1.3 kgf・m)

XR50 Motard

◇Fully tighten them.

Torque:

for two nuts: 12 N・m (1.2 kgf・m)

for mounting bolts: 20 N・m (2.0 kgf・m)

Throttle body

Pin

※Please check that the hole in the band is right on the

insulator-locating pin.

◇Connect the throttle cable to the throttle drum, and fix

the cable to the cable holder.

◇Loosely tighten the lock nut for now, and adjust the free

play at the throttle grip.

Holder

◇Fix the throttle valve to the carburetor by aligning

a notch on the throttle valve with the throttle stop

screw, and install the top cap to carburetor.

Cable

Lock nut

Drum

-10-

● Side Cover Installation

In the case of FI Ape: In the case of FI Ape:

☆ Engine Starting ☆

Fuel tank

counterparts on the frame.

※How to connect the quick connector.

○Wipe off the dirt and dust on the engine.

◇Fix the left side cover by fitting three bosses on this

◇Fix the fuel tank onto the frame, and screw up the bolt.

Once you have disconnected the quick connector, it

○Turn ON the fuel cock and ignition key, and start

cover into the frame.


is advisable to change the retainer and joint rubber

the engine.

◇Install the fuel pump unit.

Bosses with new ones.

Work only in a well-ventilated place.


１．

○Check for any abnormality such as an abnormal

Fuel tank

Mount bolt

holes in the connector together, install the retainer to

sound.

and fix the bolt.

Right side cover

Bolt

Left side cover

COPY

Hook

Collar

Seat

Fuel pump unit

& cover

Bolt

Collar

Connector


the connector.

Join together

Retainer

○If nothing abnormal is detected, carry out a

shakedown for about 30 to 50 km, and check the

valve clearance again.

※In the case of Fl ape, keep the gasoline coce on.

Work only when the engine and the muffler

are cool.

○Carry out a shakedown again for about 100 to 150

km.

○After the shakedown, double-check for any

abnormality such as an abnormal sound and

blow-by gas.

(If any abnormality is detected, disassemble the

engine again and check each section.)

Never re-use parts which cannot be re-used.

To those who are installing this Kit onto CB50

It is likely that, with age, parts will wear, wear away or get damaged.

and, as shown in the picture below, align the grooves

(or the recessed portions) of the retainer with the joint

rubber. Press in the connector until it clicks. If you

cannot easily install the connector, apply a thin coat

of engine oil to the joint.

Connector

Joint rubber

◇On CB50, fix the right and left side covers to the

Check among others a seal, bearing and journal.

Where necessary, repair or replace these parts.

frame by attaching each three hooks to the

● About point ignition

Join together

※If the ignition timing is out of alignment, the engine

does not perform to the full and may fail.

Check the ignition timing and point gap. If you are

not technically experienced or skilled, we

recommend you to ask a technically-reliable

specialist shop for the work.

Installation of Seat and Tank

in the case of Ape

◇Install the fuel tank to the frame with the bolt.


XR50 Motard

Bolts &Collars

the connector is firmly held by a lock tab and

connected securely.

◇Install right and left side covers and tighten them with

flange bolts to the specified torque.


★ Examination of ignition

Bolt

Collar

Lock tab

timing

◇Using a timing light, check that at the time of idling

at 1,500 rpm, the “F” mark on the flywheel aligns

◇If not, check the point gap.

◇Fit the hook in the front on the back side of the seat

into the frame and fix it by tightening two bolts.


Hook

Seat

●Fuel Hose Connection



◇Connect the fuel tube with the fuel petcock, and fix it

with a tube clip.

Connector

2P coupler

★ Examination of point gap

◇Change the contact breaker, if the point is rough,

partially worn or stained

◇Turn the flywheel counterclockwise until the point

gap becomes the widest.

◇Measure the point gap with a thickness gauge.

Specified value of point gap: 0.3 ~ 0.4 mm

◇In case the measured value is outside the

specified one, adjust the point gap.

check for fuel leakage. (At this point, never start the

engine.)

★ Adjustment of point gap

◇Adjust the point gap by loosening the screw

holding the breaker and by moving the contact

breaker with a flat tip screwdriver.

◇Adjust the point gap so the value is within the

specified value. And check again the ignition

timing using a timing light.

◇In case the point gap and ignition timing cannot be

adjusted, change the contact breaker.

◇Referring to the above, connect the quick connector

on the side of the throttle body.

Bolts


◇Please separately purchase an FI Controller

available as an optional extra, which please install

following the instructions in its Instruction Manual.

-11-

●Cautions Before Running

① About fuel

Always replace the gasoline with high-octane gasoline when regular gasoline is remaining in the fuel tank.

② Change of sprocket

※ 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, please make the sprockets to be with

a high gear ratio.

◇ Ape & XR50 Motard: The referential secondary reduction gear ratio of S-Stage is 2.5 (when the driver weighs 65 kgs).

The secondary reduction gear ratio is figured out by the following calculation: The number of teeth of the driven sprocket on the rear side ÷ the number

of teeth of the drive sprocket on the engine side.

Example: 35T (driven sprocket) ÷ 14T (stock drive sprocket ＝ 2.5 (secondary reduction gear ratio)

◇ CB50: The referential secondary reduction gear ratio of S-Stage is about 2.9 (when the driver weights 65 kgs).

Example: 35T (driven sprocket) ÷ 12T (stock drive sprocket ≒ 2.9 (secondary reduction gear ratio).

● Other notes

② Thermometer

COPY

①Oil Cooler(Ape / XR Motard)

◇The installation of this Kit increases the heat release value of the engine, set off by the increase in power. Therefore, we recommend that you equip your

motorcycle with an oil cooler Kit (09-07-2155: 4 fins, 5 oil lines, 09-07-2156: 3 fins, 4 oil lines) for long-hour high-load driving.

◇ A stick-type temperature sensor is installable on the cylinder side of this kit.

◇ For more powerful output, we recommend you to install our sports camshaft and Carburetor Kit.

・Sports Cam Shaft Kit: For carburetor Ape, CB 50, and XR Motard: 01-08-040

：For FI Ape: 01-08-0123

・Carburetor Kit

PC20 (with a filter): 03-05-318

PC20 (without a filter): 03-05-317

・FI Controller:

FI Controller for S-Stage: 03-05-0014

-12-

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

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