Takegawa Super cool oil cooler kit User manual

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Instruction Manual for Super Cool Oil Cooler Kit
(Mount-on-Super head+R, Oil Hose Type)
Item No.
Fits
Frame Nos
：０９−０７−８８０１ (3-fin / Super Cool)
：Monkey and Gorilla
：Z50J-1300017〜
(Models equipped with a die-cast clutch cover)
Read all instructions first before starting the installation
◎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 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.
◎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'.
◎This kit is for exclusive use only in the bikes of the models and frame Nos as mentioned in the top right-hand corner of this page, but limited to bikes
fitted with a die-cast clutch cover and Super Head+R, of TAKEGAWA-make. Please note that this kit is not for use in any other models.
◎Please order repair parts referring to Item Nos and reference Nos described in this manual. Should you have any questions about the products, please
kindly contact your local motorcycle dealer.
◎If the hose interferes with the frame, it is advisable to wind something like a spiral tube around the hose as a protection against the interference.
・Thank you for purchasing one of our TAKEGAWA-made 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 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.
・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.)
・Keep plastic bags for packing the 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 accumula
tion of gasoline is at high risk of explosion, work in a well-ventilated place. (Otherwise it may cause a fire.)
The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the
following warnings.
WARNING
・Always try to drive your motorcycle at a 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 for slack in parts like screws. If you find slack ones, screw them securely up to the specified
torque. (Otherwise, improper tightening may cause parts to come off.)
・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.
・Never forget to check the oil level before starting the engine. If the oil level is below the required level, add oil. Besides, change oil when time
has come to replace the oil, or when your motorcycle has already traveled the distance, specified in the instruction manual or service manual.
The following show the envisioned possibility of injuries to human bodies and property damage as a result of disregarding the
following cautions.
CAUTION

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１４
５．Attach a cushion rubber to an oil cooler stay, and attach a collar to
the cushion rubber.
※Fit a collar through a cushion rubber into the L-shaped-standing stay.
０９―０７１―０２２
００９―０７１―０３５
１
２
３
４５６
７
８９１０ １１ １２
１３
１．Make sure the bike is secure on level ground.
２．Prepare an oil container, and remove two socket cap screws on the
inspection cap at the bottom of the cylinder head in order to remove
the inspection cap.
※ Be careful about the engine oil which will flow out when you remove
the inspection cap.
３．Attach the supplied O-ring to the oil cooler bracket.
４．Install the oil cooler bracket to the cylinder head, and tighten it to the
specified torque.
Torque: 6 N･m (0.6 kgf･m)
６．Attach the oil-cooler stay to the oil-cooler COMP with a 6x20 button
head screw, and tighten it to the specified torque.
Torque: 10 N･m (1.0 kgf･m)
Kit includes:
When the oil hose is connected to the clutch cover, be sure to install a supplied oil hole plug or an extra-cost thermo unit
(ItemNo.02-01-5002).
Please take note that when neither of them is installed, the engine oil will not circulate through the oil cooler.
Safety Precautions for Using the Oil Cooler Kit
〜Installation Instructions〜
∴Please order repair parts by indicating the Repair Part Item No. as listed above. As you see from the list, depending
on the repair parts, in some cases we may not be in a position to accept your order for a single item in the quantity
of one.
No. Part Name Qty Repair Part Item No. In packs of
1Oil cooler COMP. 109-072-006 1
2Oil hose, 195 mm 109-070-060 1
3Oil hose, 315 mm 109-070-061 1
4Button-head socket cap screws 6X20 2BW-00-0010 5
5Flange bolt 6X40 1BW-00-0016 4
6Flange U nut 6mm 1BW-02-0003 6
7Oil cooler bracket 109-071-035 1SET
8Oil cooler stay 255302-SPH-T00 1
9Rubbers 2BW-01-0008 4
10 Collars 2BW-01-0012 4
11 O-ring 1000-13-061 2
12 Sealing washers, 10 mm 209-071-015 10
13 Adapters, M10 209-071-022 1SET
14 Oil hole plug 119331-GEF-T00 1

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1２．Add about 80cc of engine oil, and then start the engine.
After checking each hardware for oil leakage, stop the engine and
wait for about one minute. Then check the oil level through an oil pot
window in the clutch case cover. If the oil level is low, add engine
oil.
７．Put the oil cooler bracket between two oil cooler stays, pass a 6x40
flange bolt, and tighten it with a flange U-nut.
Torque: 10 N･m (1.0 kgf･m)
８．Unscrew an oil plug bolt on the clutch cover.
Attaching a 10mm sealing washer onto an M10 adapter, fix the adapter.
When tightening, be careful not to hit the cover with a spanner or else.
Otherwise, the paint may be scraped.
NOTE : Be sure to tighten to the specified torque.
Torque: 14 N･m (1.4 kgf･m)
９．Temporarily fit the oil hoses into the M10 adapters. Referring to the
picture below, fix the 195mm oil hose at your right hand, and the
315mm oil hose at your left hand, when seen in the direction of travel．
１０．Attach the oil hose so it does not interfere with other hardware
heavily. Attach the oil hose on the right to the right side of the oil
cooler, and the oil hose on the left side to the left side of the oil
cooler, all of the driving direction. After the hoses have been run
properly, tighten the fittings to the specified torque.
※ When tightening the fitting, be sure to hold the adapter with a
spanner.
CAUTION: Be sure to tighten to the specified torque.
Torque: 10 N･m (1.0 kgf･m)
Thermo unit
１１．(In the case of installing a thermo unit)
Detach the hole cap and fix a thermo unit.
※ Please see the instruction manual for the thermo unit.
(In the case of not installing the thermo unit)
・Detach the thermostat hole cap, and fit a supplied oil hole plug
into the oil hole.
・Apply engine oil to the O-rings of the
thermostat hole cap, and tighten the hole cap to the specified
torque.
Torque: 13 N･m (1.3 kgf･m)
ＩＮ ＯＵＴ
Thermostat hole cap Oil hole plug
3-5-16 Nishikiorihigashi Tondabayashi
Osaka Japan
TEL : [phone]
FAX : [phone]
URL : http://www.takegawa.co.jp
NOTE：When the cooler hose is detached
from the clutch cover and the plug
bolt is fastened
(=the same state as at the time of your
purchase), be sure to remove either
the oil hole plug or thermo unit
whichever remains installed.
When you start the engine with
either of them still being installed,
there is a possibility that the engine
will break down because of the oil
passage blockage.
195mm oil hose
315mm oil hose