Takegawa DESMO TWINCAM 4V User manual

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‑A1‑ Nov./29/12
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.
Important Notice
☆Secondary kick starter engine
☆DESMO-124
☆TAF5SP (Super Street)
☆Special Clutch (wet)
：Z50J -2000001〜
：AB27-1000001〜1899999
Compatible models
Monkey / Gorilla
Item No.：０１―００―９４３０
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.
Engine Complete KIT :

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‑A2‑ Nov./29/12
・This Kit is designed for closed course competition purposes only. So please do not drive on a public road after the installation of this Kit.
・Before starting the installation, make sure the engine and muffler are cool at below 35 degrees Celsius. (Otherwise, you will burn you.)
・Prepare right tools for the work. (Otherwise, the installation with improper tools could cause breakage of parts or injuries to you.)
・As some products and frames have sharp edges or protruding portions, please work with your hands protected. (Otherwise, you will suffer injuries.)
・Always use new gaskets, seals and the like. The continued use of the worn or damaged ones will cause engine trouble.
The following show the envisioned possibility of injuries to human bodies and property damage as a result of disregarding the following cautions.
CAUTION
・Those who are technically unskilled or inexperienced are required not to do the work. (Improper installation because of insufficient skill or knowledge could lead to parts breakage and subsequently to accidents.)
・Before doing work, place the motorcycle on level ground to secure your motorcycle for safety's sake. (Otherwise, your motorcycle could overturn and injure you while you are working.)
・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.)
・As gasoline is highly flammable, never place it close to fire. Make sure that nothing flammable is near the gasoline. (Otherwise it may cause a fire.)
・Tighten to a specified torque using a torque wrench. (Otherwise, improper tightening may cause the bolts or nuts to get damaged or come off, leading to accidents.)
・Never use the parts unspecified by us. (This may lead to parts breakage and consequent 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.)
・When you notice something abnormal with your motorcycle while riding, immediately stop riding and park your motorcycle in a safe place to check what has gone wrong.
(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. Otherwise, the driver is likely to be subject to death or serious injury in an accident.
WARNING The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the following warnings.
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 this product not in conformity with the instructions in this Manual.
○While working on this product, be sure to proceed with the proper work in accordance with the instructions.
○Be sure to prepare the genuine service manual of the compatible models and work as instructed. The service and repair information contained in this installation instructions and the genuine service manual are intended for
use by qualified, professional technicians.
Be sure that any person who attempts service or repairs without the proper experiences, tools and equipment ask specialty shops or professional mechanics.
○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.
○Do not use other manufacture’s ignition parts, or it will cause the failure.
○The necessary parts for this kit should be all TAKEGAWA-recommended parts. Always use our recommended parts.
○Use TAKEGAWA-recommended fuel and engine oil.
○Do not keep engine running in idle position for long period of time. It exceeds engine temperature, which cause the damage of the engine.

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●Use of Lightweight Outer Rotor ACG
◇SS-outer rotor is equipped as standard .Rotor body is a compact design and it weighs 536g. The best ignition
timing is set up exclusively for this complete engine and the quick response has been achieved.
Features
●Use of Plated Cylinder:
◇We have installed the oil jet which works to jet-spray the oil to the rear side of the piston from crankcase oil
line in order to cool the piston.
●Use of Oil Jet:
●Use of Wet Multiple-Disk Clutch:
◇We have installed a multiple-disk clutch with 5 disks onto the transmission main shaft so it can respond to
even high output powers.
This arrangement serves to improve durability of the crankshaft and throttle response. In addition, we have
installed a highly-reliable cartridge oil filter on the clutch cover. The clutch cover is so structured that a new
line is prepared for taking out an oil cooler from the clutch cover and a thermostat can be installed as an
option.
●Use of close ratio transmission:
◇The close ratio transmission is designed to enable smooth shift up and down and cornering, and, moreover,
effective transmission of engine power.
◇This cylinder is aluminum one-piece construction and the ceramic chrome plated inner wall allows the
additional wear-resistance and the reduced friction loss. It also features both high gas tightness and
durability.
●About our DESMO head
◇Most 4 stroke combustion engines use a camshaft and a valve spring to open and close the valves, but the
DESMO structure uses a specially shaped camshaft that forces the valve open and shut.
Thus, since it does not use a valve spring, there is no surging of the valve spring when driving at high speeds.
And another special feature is the very small amount of friction exerted on the camshaft.
The cylinder head uses a twin cam of 4 valves, so the intake valve diameter is 22mm and the exhaust valve
diameter is 19mm.
Within the limited space of the horizontal engine, 8 rocker arms and 2 camshafts are distributed like a precision
instrument, providing proof-positive of the technical power of our company.
In addition, we have tested a large number of combustion chambers of differing shapes, and we have utilized
the shape with the highest efficiency ratio.
Mutual compatibility of the exhaust port and the exhaust system has been achieved by using the same as our
Super Head and stock head.
In addition, the cam gear related parts and the intake manifold are also compatible with the present DOHC
engine.

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‑A4‑ Nov./29/12
No. Part Name Qty Repair Part Item No. In packs of
1Engine COMP. 1
2Spark plug, ER8EH 1NGK-ER8EH 1
3Intake manifold １1
4Socket cap screw, 6 x 20 2 2
5Socket cap screw, 6 x 15 2 2
6Norma Torro Band 1 1
7Inlet pipe gasket 1 1
8Exhaust pipe gasket 100-01-0064 2
9Clutch cable COMP., 910 mm 122870-181-T00 1
10 Braided hose, 8 x 1 m 1 1
11 Hose clamp, 13.1 2 2
12 Spark plug cap COMP. 130700-DSM-T00 1
13 Plug cord joint 100-01-1012 1
14 High tension cord, 500 mm 100-01-1043 1
15 Hyper CDI 105-03-0003 1
16 Head cover gasket set 106111-DSM-T00 1
17 Plug socket, 13 mm 100-00-0247 1
18 Ball point driver, 4 mm 1
19 Alumi special (5 g) 100-01-0001 1
06171-D4H-T00
00-07-0070
※Please order repair parts with the Repair Part Item No. Without the repair part item NO.,
we may not be able to accept your orders.
Some parts are only available as a set. In this case, please order them with the set
number.
〜Kit contains〜
１
１６
３
７４
１４
１２
１１
１０
８
２
９
１７
５
６
１８
１３
１５
１９

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Type 4-cycle gasoline
Displacement 123.7cc
Number of cylinder and arrangement Horizontal single cylinder
Cooling method Air-cooling
Valve train DOHC(desmodromic) valve, chain / gear drive.
Chamber design Pentroof (Hemispherical) type
Bore and Stroke 54mm x 54mm
Compression ratio 12.5 : 1
Intake 25
Exhaust 20
Valve timing: (1mm lift)
Intake open 15°BTDC
closed 47°ABDC
Exhaust open 45°BBDC
closed 10°ATDC
Lubricating method Combined use of force feed system & splash lubrication system
Pump type Trochoid type
Capacity 0.8 liter
Fuel to be used
Ignition system C.D.I. ignition
Spark plug NGK-ER8EH
Starting method Kickstarter system
Power transmission
Clutch Wet multi-disk
Operating mode Mechanical
Transmission
Type Constant mesh, 5-speed return
Gear ratio
1st speed 2.357 (33 / 14)
2nd speed 1.764 (30 / 17)
3rd speed 1.400 (28 / 20)
4th speed 1.136 (25 / 22)
5th speed 1.000 (24 / 24)
rear-wheel-drive mechanism
Type Chain drive
Main Reference Value
High-octane gasoline
（research method: over 97 octane value)
Camshaft type
Items Frequency Refer to page
Clean and Inspect Spark Plug Every 200km P-C1
Inspect Valve Clearance Every 500〜600km
Change Engine Oil Every 1000〜2000km P-C1
Adjust and Inspect Carburetor Each time Depend on Carburetor type
Replace Oil Filter Every 1500〜2000km P-C2
Adjust Clutch Cable Every 250km P-C2
Inspect Clutch Friction Disc Every 1000km See Service Manual
Inspect Piston and Piston Ring Every 1000km See Service Manual
Inspect Piston Pin Every 2000km See Service Manual
Inspect Crankshaft Every 1000km See Service Manual
Inspect Cylinder Head and Cylinder Every 2500km See Service Manual
Inspect Crankcase Every 2000km See Service Manual
Inspect and Adjust
※Maintenance period in the table is a guideline. You might need to work more frequently
depending on the motorcycle usage or condition.
We recommend more frequently maintenance than the maintenance period.

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Stock fork (Inapplicable) ×
Our φ30 Upright Front Fork
Spec Modification (See P-D4)
Top Bridge /
Stock fork (Inapplicable) ×
Our Top Bridge & Stem Kit or Front Fork Kit
Steering stem Spec Modification 60mm Offset (See P-D4)
We recommend the modification to match the front fork and tire size.
(See P-D4)
We recommend to use it according to the heat increase.
(See P-D3)
Drive / Stock (Inapplicable) × Final Gear Ratio 2.188〜2.063 (for 10-inch)
Driven sprocket Spec Modification (See P-D2)
Equipped as necessary
(See P-D4)
Tyre
Compatible Specifications Data Chart
Larger wheel (10-inch) is recommended according to the power increase.
Front Fork
Oil catch tank Need to Install
Rear Fork
Oil cooler
〜Precautions of Use〜
●An Engine NO. (Serial No.) is stamped on this engine as identification.
Please specify your Engine NO. when ordering repair part or contacting us.
About fuel:
◇Whenever regular gasoline is remaining in the fuel tank, always replace it with high-octane gasoline.
About oil cooler:
◇The installation of this product increases the heat release value of the engine, set off by the increase in
power. We recommend you, therefore, to install an oil cooler kit, for a long-time high-load running, which
keeps oil at appropriate temperatures and prevents such troubles as oil film shortage at high temperatures.
●In case you use the breather cap, be sure to use an oil catch tank at the same time.
Due to large displacement engine, blow- by gas volume may increase. Larger capacity catch can are highly
recommended. (approx 500 cc)
About the specifications of motorcycle to equip
◇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.
For Monkey / Gorilla, modify the chassis if necessary after checking whether the installation is possible
referring to the following parts and optional parts of P-D1〜D4.
3-5-16 Nishikiorihigashi Tondabayashi Osaka Japan TEL:[phone] FAX:[phone] URL:http://www.takegawa.co.jp
Co.,Ltd.
Engine No.stamped here.
About upper limit of revolution:
◇Max rpm may vary by the camshaft and engine specification, always use taco meter to avoid over-rev the
engine rpm.
124cc : Intake camshaft : 25
Exhaust camshaft : 20
Maximum rpm : 12000 rpm
138cc : Intake camshaft : 25
Exhaust camshaft : 25
Maximum rpm : 11500 rpm
◇Take note that engine racing and sudden acceleration, particularly in the 1st or 2nd gear, tend to exceed the
upper limit of revolutions.
Over revolutions will result in nonsmooth revolutions of the engine, not only adversely affecting the engine
life, but also possibly breaking the engine in the worst case.
Rearsets:
◇To use rearsets, you may need to modify the drive sprocket cover.

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‑B1‑ Nov./29/12
●Installation of engine
●Remove the engine ●Connect ACG
Clutch cable
Clutch lever COMP.
〜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.
☆Please Note: Illustrations and photos may vary from actual hardware.
○Install the engine COMP. to the frame referring to
the relative service manual for the motorcycle.
Caution : Be sure to follow the specified torque.
Warning : Do follow the instructions in the service
manual.
●Installation of clutch cable:
○Attach a clutch cable to the clutch lever, and route
the cable to the clutch cable receiver, being careful
not to stretch it too tight.
○Turn the clutch release pinion clockwise until it
comes to a halt, and put the plain washer into the
release pinion.
Clutch release arm
Arm spring
Plain washer
20〜25N・m
(2.0〜2.5kgf・m)
○Remove the engine and carburetor from the
motorcycle referring to the service manual of your
vehicle.
○Replace the CDI with the supplied CDI referring to the
service manual of your vehicle.
○Connect the wire from Engine COMP and the coupler
from the motorcycle.
☆If you set up the main wire harness as a racing
purpose, connect the wires referring to the attached
wiring diagrams.
(See P-B6)
☆For those who ordered without ACG
・Remove the generator cover and install the
generator and flywheel following the instructions
of your ignition parts.
Caution : Be sure to follow the specified torque.
Torque:20 〜25N・m (2.0〜2.5kgf・m)
Lock nut Adjusting nut
Adjust bolt
Removaldirection
Flange bolt
Clutchreleasearm
○Install release arm with faced gap back, then hock
the spring to the arm and case while fully pull the
arm.
○Attach the cable at cable receiver.

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‑B2‑ Nov./29/12
○Attach an air filter, which please secure by
tightening a band.
○Adjust the free play at the throttle grip to be about
5 mm by turning the adjuster of the throttle cable.
☆Follow the instructions of your throttle cable to
adjust the free play.
Clutch free play :
10 to 20 mm at the clutch lever end
●Inspection:
○With the engine turned off, shift the transmission to
the first gear. Then, check that the rear wheel
rotates when you move the machine, squeezing
the clutch lever, and that the rear wheel does not
rotate when you have released the clutch lever.
●Installation of carburetor:
○Route the supplied throttle cable along the frame just
like the stock throttle cable was routed.
○Pass the throttle cable through the lower throttle
housing, and connect the inner cable to the throttle
pipe.
And attach the throttle housing to the steering handle.
※Apply grease to the rubbing surface of the throttle
pipe, cable end and the cable taking-up portion on the
pipe.
○Put a inlet pipe gasket between the cylinder head
and the inlet pipe, and tighten it with 6x20 socket cap
screw to the specified torque.
○Fasten the carburetor insulator, to be used on the
inlet pipe, with the supplied two socket cap screws.
○Remove a float chamber, and then a main jet. Attach
a supplied main jet #110 and slow jet #35, and then a
float chamber.
○Detach a top cover of the supplied carburetor, and
pull out the spring and throttle valve.
Pass the inner cable of the throttle cable through the
carburetor top cover and then through the spring.
And compressing the spring, fix the top cover and all
to the throttle valve. Fix the throttle valve to the
carburetor by aligning a notch on the throttle valve
with the throttle stop screw.
☆In the case of PE28:
Fits only the Monkey
∴NOT installable onto the Gorilla
○Insert the carburetor into the insulator, and fasten
them with a clamp band.
About 5 mm
More free play
Adjuster
Less free play
Snap the throttle a few times to make sure that the
throttle moves smoothly without sticking and that
the throttle valve is fully open. And check that the
throttle has free play even when a steering handle
is turned all the way to the right or to the left.
○Insert a fuel tube and fasten it with a tube clip.
Open the fuel cock and check for oil leaks.
10 to 20 mm Clutch lever
Caution : Be sure to follow the specified torque.
Torque: 10 N･m (1.0 kgf･m)
Screw6X20
Caution : Be sure to follow the specified torque.
Torque: 10 N･m (1.0 kgf･m)
○Attach the flange bolt to the release arm, and tighten
the bolt to the specified torque, pressing the arm.
Lock nut Adjusting nut
Adjust bolt
Caution : Be sure to follow the specified torque.
Torque: 10 N･m (1.0 kgf･m)
Caution : Be sure to follow the specified torque.
Torque: 10 N･m (1.0 kgf･m)
○Adjust the free play at the clutch with the adjuster
on the clutch cable, then tighten the locking nuts to
the specified torque, and cover the clutch cable
adjusters at both ends with rubber caps.

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‑B3‑ Nov./29/12
○Adjust the free play at the throttle grip to be about
5 mm by turning the adjuster of the throttle cable.
☆Follow the instructions of your throttle cable to adjust
the free play.
○Dispose of the blow-by gas from the crankcase by
yourself.
(Some races and regulations stipulate the blow-by
gas disposal.)
○In sending back the blow-by gas to the carburetor,
connect the blow-by hose with the union on the
air-filter.
(See Optional parts chart on P-D1)
○Install an optional kick starter arm.
●Engine oil
○Remove the cap and add 850cc of engine oil.
○Referring to the chart below, choose the engine oil
whose viscosity matches the region and outside
temperature.
○Install the oil inlet cap.
○Remove the top cover from the carburetor, and pull
out the spring and the throttle valve.
Pass the inner cable of the throttle cable through
the carburetor top cover and then through the
spring. And compressing the spring, fix the top
cover and all to the throttle valve. Fix the throttle
valve to the carburetor by aligning a notch on the
throttle valve with the throttle stop screw.
☆In the case of VM26:
○Insert the carburetor into the insulator, and fasten
them with a clamp band.
○Attach an air filter, which please secure by
tightening a band.
Snap the throttle a few times to make sure that the
throttle moves smoothly without sticking and that the
throttle valve is fully open. And check that the throttle
has free play even when a steering handle is turned
all the way to the right or to the left.
※In the case of installation to any model of the Gorilla,
replace the pre-installed fuel cock with the supplied
cock. Adjust the direction of the fuel cock and fasten
the nut to the fuel tank.
More free play
Adjuster
Less free play
About 5 mm
○Insert a fuel tube and fasten it with a tube clip. Open
the fuel cock and check for oil leaks.
(Do not leave the cock open for many hours.)
Caution : Be sure to follow the specified torque.
Caution : Be sure to follow the specified torque.
Torque: 5〜6N･m (0.5〜0.6 kgf･m)
Oil Inlet Cap

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‑B4‑ Nov./29/12
○Attach the plug cap to the spark plug.
○Thoroughly wipe off dirt and dust on the engine.
○Turn on the gasoline cock and the ignition key. Pull a
choke lever to start the engine. Gradually loosen your
grip on the lever, and warm up the engine till the
revolution becomes smooth. And then return the lever
fully back to its original location.
If the engine does not run idle after warming-up, or it
runs idle at high revolutions, adjust the revolutions
with the throttle stop screw.
○Carry out again a shakedown up to about 50 to
100 km.
○After the shakedown, check for malfunctions such
as unusual noises or blow-by gas.
(If there is any malfunction, disassemble the engine
again to check each part.)
●Start engine
○Install the drive chain referring to a genuine
service manual or instruction manual for the
relative rear fork.
In the direction of the
chain’s movement
Chain clip
○Attach a supplied exhaust pipe gasket to the exhaust
port.
○Check that the ignition key and gas cock are turned
off.
○Keep kicking the starter for a while till the engine oil
circulates all around the engine.
○Install the spark plug. Lightly apply the “Aluminum
Special”, the heat-resistant lubricating agent, to the
threaded portion on the plug. And tighten the plug.
○Install an exhaust muffler according to the installation
instructions of the relative exhaust muffler.
∴Always keep the oil to the specified level.
(Use the same grade and brand oil.)
○Check for malfunctions such as unusual sounds.
○If no malfunction is detected, do the setting of the
carburetor.
(See the attached sheet)
Caution : Never reuse parts which are not
suitable for reuse.
Warning: Those who are technically unskilled or
inexperienced are required not to do
the work.
●Install the exhaust system
○Install the change pedal.
Caution : Be sure to follow the specified torque.
Torque: 8〜10 N･m (0.8〜1.0 kgf･m)
○Stop the engine once.
Wait for a few minutes and keep the motorcycle
level to the ground, and then check the oil amount
with oil level gauge on right crankcase.
Warning : Be sure to do the work in a well-
ventilated place.
●Installation of drive chain
○Install the drive sprocket.
Caution : Be sure to follow the specified torque.
Torque: 10 〜12N･m (1.0 〜1.2 kgf･m)
○Remove generator cover.(5 bolt)
Warning : Do follow the instructions in the service
manual.
Caution : Be sure to follow the specified torque.
Upper limit
Lower
limit
Oil site window
Sprocket Plate
Chain Bolt
Plate

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‑B5‑ Nov./29/12
◎About Optional Clutch Parts:
After removing a thermostat hole cap, install the
thermo unit.
※For details, see the Instruction Manual for the
thermo unit.
※The thermo unit alone does not function.
(Installation of thermo unit)
（Oil Cooler Installation）
●In case a thermo unit is to be installed:
１．Install a thermo unit.
２．Unfasten two oil plug bolts, and install an adapter
suitable for the kind of hose you will use. Then
connect the hose.
※Please see the instruction manual for the thermo
unit.
※Please see the instruction manuals for the oil
cooler kit and the adapter.
Rubberhose Slim-line hose Allegri’s hose
ＩＮ ＯＵＴ
Thermostat hole cap Oil hole plug
In case an oil cooler is not installed:
NEVER install a thermo unit or an oil hole plug. And in
case the thermo unit and / or an oil hole plug is
installed, DO be sure to remove it or them.
◎Relevance of Front Fork and Tire
оClamp the top bridge at the highest point of the
straight portion to avoid the tapered portion of
front fork.
※ Before installing, make sure that no
interference occurs when the front fork is fully
bottomed.
○φ 30 Upright Front Fork
Tapered portion
Caution：NEVER install a
thermo unit or an oil
hole plug if you do
not connect an oil
hose to the clutch
cover.
There is a
possibility that the
engine is damaged
due to the oil
passage blockage.
Caution：There is a
possibility that the
engine is damaged
because the oil
passage will be
blocked when the
thermo unit or an oil
hole plug is installed.
●In the case of not installing the thermo unit
１．Detach the thermostat hole cap, and fit an oil hole
plug (option) into the oil hole.
２．Apply engine oil to the O-rings of the thermostat
hole cap, and tighten the hole cap to the
specified torque.
Caution : Be sure to follow the specified torque.
Torque: 13 N・m (1.3 kgf・m)
３．Unfasten two oil plug bolts, and fit an adaptor to
match the hose to be used. And connect the hose.
※ For details, see the Instruction Manuals for an Oil
Cooler Kit and an Adaptor.

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‑B6‑ Nov./29/12
Generatorside
黄1
黄2
緑
青/黄
黒/赤
若葉/赤
Bikeside
黄
白
緑
青/黄
黒/赤
若葉/赤
機能
灯火用AC出力（AC電源用）
灯火用AC出力（DC電源用）
メインアース（GND）
パルスジェネレーター信号
点火用AC出力
ニュートラルスイッチコード
Yellow1
Yellow2
Green
Blue/Yellow
Black/Red
LightGreen/Red
Yellow
White
Green
Blue/Yellow
Black/Red
LightGreen/Red
Function
LightingACoutput(forACpower)
LightingACoutput(forDCpower)
MainGND
PIckup pulse
Ignition ACoutput
NeutralSwitch
Racing use
ACGenerator
forSpark
AC Generator
forLighting
TAKEGAWA C.D.I.
Green
Black/Red
Black/Red Blue/Yellow
Green
Green
Yellow 1
TimingPulse
Generator
Neutral
Switch
Light Green
/Red
Black/Yellow
Engine Stop Switch
Black/White
Yellow 2
[Yellow 1][Yello 2][Light Green/Red]
Wires are unconnected.
Ignition Coil
Super Street
outer rotor kit
Blue
/Yellow
ON:STOP
※

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‑C1‑ Nov./29/12
●Spark plug:
○Detach a plug cap, and then a spark plug with a
plug wrench.
○With a wire brush or a plug cleaner, clear the plug
electrode section of the accumulated residues.
○Check the plug gap with a thickness gauge.
And when the gap deviates from the benchmark,
adjust it by bending the electrode section.
○Check if the electrode section is worn out, corroded
or burnt-out, or its insulator is damaged.
When necessary, change the spark plug.
○With a wire brush or a plug cleaner, clear the plug
electrode section of the accumulated residues.
○Check the plug gap with a thickness gauge.
And when the gap deviates from the benchmark,
adjust it by bending the electrode section.
○Warm up the engine within a few minutes to normal
operating temperature.
○Prepare an oil container under the drain bolt.
And drain the oil while the engine is warm.
●Oil Change: ○Add the engine oil in the specified amount.
∴Recommended oil:
SAE 10W - 40 20W - 50
API class, SF grade engine oil
∴Oil amount:
When oil change ONLY :750cc
When rebuilt the engine :800cc
○Referring to the chart below, choose the engine oil
whose viscosity matches the region and outside
temperature.
CAUTION Be sure to use a torque wrench and strictly keep the specified torque.
∴Gap
Benchmark : 0.6〜0.7 mm
Electrode
section
Gap
Standard
・NGK : ER8EH
Plug with high thermal value (Cold type)
・NGK : ER9EH
Relationship between
temperatures and viscosity
Outside
temperatures
○Install the drain bolt, and tighten it to the specified
torque.
○Install the oil inlet cap.
○Warm up the engine within a few minutes to normal
operating temperature.
○Stop the engine once. Wait for a few minutes and
keep the motorcycle level to the ground, and then
check the oil amount with oil level gauge on right
crankcase.
∴Always keep the oil to the specified level.
(Use the same grade and brand oil.)
Caution : Be sure to follow the specified torque.
〜Inspections and Adjustments〜
WARNING The inspections and adjustments are intended for use by qualified professional mechanics. Be sure that any person who does not have the proper
technique, experiences and knowledge will never work.
○Apply a small amount of ALUMI SPECIAL on screws
of spark plug. Tighten the spark plug and install the
plug cap.
Caution : Be sure to follow the specified torque.
Torque: 19.5 〜24.5 N・m(2.0 〜2.5 kgf・m)
○Remove the cap of oil inlet and add 750cc of engine
oil.
Upper limit
Lower
limit
Oil site window
Oil Inlet Cap

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‑C2‑ Nov./29/12
○Inspect the free play of clutch lever.
●Adjust the Clutch Cable
○Turn the adjust nut of clutch holder and adjust the
free play of clutch lever.
○If you cannot adjust the free play with the lever holder,
adjust it with the adjust nut of receiver.
○Apply a thin coat of engine oil to the O-ring on the oil
filter cover, attach an oil filter and oil filter cover, and
tighten two bolts to the specified torque.
Oil filter spring
10 to 20 mm Clutch lever
Lock nut
Adjust nut
○Unfasten two bolts on the oil filter cover, and
detach the oil filter cover, oil filter and oil filter spring.
●Change of Oil filters:
○Check the O-ring in an oil filter cover, and change
it when necessary.
○Attach a new oil filter to the filter cover.
○Place the oil filter spring at the protrusion on the
right side crankcase cover.
Oil filter
00-02-0027 O-ring
00-02-0040
Filter cover
Caution : Be sure to follow the specified torque.
Torque: 10 N・m(1.0 kgf・m)
○Tighten the lock nuts on clutch lever and clutch cable
respectively.
Caution : Be sure to follow the specified torque.
Torque: 10 N･m (1.0 kgf･m)
Lock nut Adjust nut
Adjust bolt
Cable receiver

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How to Set the Carburetor
※Set the carburetor only after warming up the engine, and then test-drive. And use a plug with the right heat value.
※Do the setting in the following manner, studying at what throttle opening position the engine starts failing.
○Jet needle (Throttle position at 1/4 - 3/4)
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 s
moothly 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.
・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.
・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.
・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.
1段目
4
段目
2
段目
5段目
1stgroove
2ndgroove3rdgroove 4thgroove
5thgroove

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‑D1‑ Nov./29/12
03-03-0321
VM26 Carburetor PE28 Carburetor
03-03-027
Item Nos Product Names
00-03-0151 Pilot jet, # 10
00-03-0152 Pilot jet, # 12.5
00-03-0153 Pilot jet, # 15
00-03-0154 Pilot jet, # 17.5
00-03-0155 Pilot jet, # 20
00-03-0156 Pilot jet, # 22.5
00-03-0157 Pilot jet, # 25
00-03-0158 Pilot jet, # 27.5
00-03-0159 Pilot jet, # 30
Item Nos Product Names
00-03-0060 Main jet, # 100
00-03-0061 Main jet, # 105
00-03-0062 Main jet, # 110
00-03-0063 Main jet, # 115
00-03-0064 Main jet, # 120
00-03-0065 Main jet, # 125
00-03-0066 Main jet, # 130
00-03-0067 Main jet, # 135
00-03-0068 Main jet, # 140
00-03-0069 Main jet, # 145
00-03-0070 Main jet, # 150
00-03-0071 Main jet, # 155
00-03-0072 Main jet, # 160
00-03-0073 Main jet, # 165
00-03-0074 Main jet, # 170
00-03-0075 Main jet, # 175
00-03-0076 Main jet, # 180
00-03-0077 Main jet, # 185
00-03-0078 Main jet, # 190
00-03-0079 Main jet, ♯195
00-03-0080 Main jet, ♯200
00-03-0081 Main jet, ♯210
00-03-0082 Main jet, ♯220
00-03-0083 Main jet, ♯230
00-03-0084 Main jet, ♯240
00-03-0085 Main jet, ♯250
00-03-0086 Main jet, ♯260
Item Nos Product Names
00-03-0137 Slow jet, ♯35
00-03-0138 Slow jet, ♯38
00-03-0139 Slow jet, ♯40
00-03-0140 Slow jet, ♯42
00-03-0141 Slow jet, ♯45
00-03-0142 Slow jet, ♯48
00-03-0143 Slow jet, ♯50
00-03-0144 Slow jet, ♯52
00-03-0145 Slow jet, ♯55
00-03-0146 Slow jet, ♯58
00-03-0147 Slow jet, ♯60
00-03-0148 Slow jet, ♯62
00-03-0149 Slow jet, ♯65
00-03-0150 Slow jet, ♯70
Item Nos Product Names Item Nos Product Names
00-03-0130 Main jet, #82 00-03-0107 Main jet, #142
00-03-0131 Main jet, #85 00-03-0108 Main jet, #145
00-03-0132 Main jet, #88 00-03-0109 Main jet, #148
00-03-0133 Main jet, #90 00-03-0110 Main jet, #150
00-03-0134 Main jet, #92 00-03-0111 Main jet, #152
00-03-0135 Main jet, #95 00-03-0112 Main jet, #155
00-03-0136 Main jet, #98 00-03-0113 Main jet, #158
00-03-0090 Main jet, #100 00-03-0114 Main jet, #160
00-03-0091 Main jet, #102 00-03-0115 Main jet, #162
00-03-0092 Main jet, #105 00-03-0116 Main jet, #165
00-03-0093 Main jet, #108 00-03-0117 Main jet, #168
00-03-0094 Main jet, #110 00-03-0118 Main jet, #170
00-03-0095 Main jet, #112 00-03-0119 Main jet, #172
00-03-0096 Main jet, #115 00-03-0120 Main jet, #175
00-03-0097 Main jet, #118 00-03-0121 Main jet, #178
00-03-0098 Main jet, #120 00-03-0122 Main jet, #180
00-03-0099 Main jet, #122 00-03-0202 Main jet, #182
00-03-0100 Main jet, #125 00-03-0123 Main jet, #185
00-03-0101 Main jet, #128 00-03-0124 Main jet, #188
00-03-0102 Main jet, #130 00-03-0125 Main jet, #190
00-03-0103 Main jet, #132 00-03-0126 Main jet, #192
00-03-0104 Main jet, #135 00-03-0127 Main jet, #195
00-03-0105 Main jet, #138 00-03-0128 Main jet, #198
00-03-0106 Main jet, #140 00-03-0129 Main jet, #200
High flow filter
AirAirAir
Shape-maintaining
stainless spring
High flow filter
Pebbles
and sand
Pebbles
and sand
Insulator
00-03-0210 00-03-0211
58mm 58mm
30mm
30mm
φ34 φ35
φ29 φ29
03-01-1064
03-01-1094 for MIKUNI VM26
forKEIHINPE28
for VM26 for PE28
For more information, please refer to our parts catalog, or log onto our Web site at
URL http://www.takegawa.co.jp
Involute throttle set
Outer length: 710 mm
09-02-0230 (Black anodized)
09-02-0232 (Gray metallic anodized)
Outer length: 810 mm
09-02-0231 (Black anodized)
09-02-0233 (Gray metallic anodized)
Standard high throttle set
09-02-0222 (710 mm in outer length)
09-02-0221 (810 mm in outer length)
90-bent high throttle set
09-02-021 (700 mm in outer length)
Fuel cock assembly
03-03-001

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‑D2‑ Nov./29/12
23T 24T 25T 26T 27T 28T 29T 30T 31T 32T 33T 34T 35T 36T
12T 1.91 2.00 2.08 2.17 2.25 2.33 2.42 2.50 2.58 2.67 2.75 2.83 2.92 3.00
13T 1.76 1.84 1.92 2.00 2.08 2.15 2.23 2.31 2.38 2.46 2.54 2.62 2.69 2.77
14T 1.64 1.71 1.79 1.86 1.93 2.00 2.07 2.14 2.21 2.29 2.36 2.43 2.50 2.57
15T 1.53 1.60 1.67 1.73 1.80 1.87 1.93 2.00 2.07 2.13 2.20 2.27 2.33 2.40
16T 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
Racing C.D.I. Magnet Kit 05-02-0511
○Excellentstartupperformancebecauseofignitionatlow
revolution. (Excellentstart-up by a kickstarter)
○Ignition timing adjustable at up to 24 degrees,
○Integral ignition coil with built-in CDI unit,
○Fully-covered stator coil to protect the ignition coil,
○Weight saving:
R-type φ58 rotor: 336 g
Stator, including cords: 383 g
Ignition coil, including cords: 370 g
○“ROSSA” (red) as proof of high performance
※No charging functions
Kick starter arm
(Steel-forged) (Aluminum-forged)
02-08-0043 09-10-006
(Back step should not be installed.)
Clutch lever assembly
02-01-028 (black)
02-01-0282 (silver)
Quick lever ASSY.
02-01-0601
Steel Drive Sprocket
02-05-01 (12T Standard)
02-05-02 (13T Standard)
02-05-03 (14T Standard)
02-05-041 (15TRacing)
02-05-051 (16TRacing)
Aluminum Driven Sprocket
02-07-0635(35T)
02-07-0638(38T)
02-07-0641(41T)
02-07-0642(42T)
02-07-0643(43T)
02-07-1225(25T)
02-07-1228(28T)
02-07-1230(30T)
02-07-1233(33T)
02-07-1235(35T)
02-07-0007(23T)
02-07-025 (25T)
02-07-028 (28T)
02-07-030 (23T)
Gear Ratio (Final)
Driven
Drive
Steel Driven Sprocket

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‑D3‑ Nov./29/12
Clutch cover
Super cool
Allegri braided oil line
Slimline hose 09-07-2621 09-07-2624
Rubber hose
3Fin
4Line 4Fin 5Line
Outlet Steering Stem mount
Oil cooler
Mounting Position
For more information, please refer to our parts catalog, or log onto our Web site at
URL http://www.takegawa.co.jp
3-Fin 4-Line A
00-07-0045
4-Fin 5Line A
00-07-0004
Super cool type A / AL (with internal threads)
SuperCool TypeAis anoilcooler comingwith internalthreadsfor attachinganadaptor totheoil cooler.Asfar asourproducts areconcerned,thisinternalthread
isusedintheSuperCoolKitwitharubberhoseandaSlimlinehose.Withanextra-costfittingadapter,theAllegrimeshhosecanalsobeattached.However,please
beadvisedthatAllegrimeshhosesare designed for exclusive use, not for general use.
Oil cooler
Oil cooler plates for Oil Coolers A & B
For Super Cool 4F6L (A) / 4F5L (B)
09-07-021 (blue)
09-07-022 (red)
09-07-023 (gold)
For Super Cool 3F4L (A) / 3F4L (B)
09-07-025 (blue)
09-07-026 (red)
Oil cooler guard
09-07-006(3F4L)
09-07-002(4F5L)
Compact cool
Theoil“CompactCool”is designed more compact compared to our current oil cooler and the best for mini motorcycles such asMonkey/Gorilla.Theoilpassageis
ourStandardTypeand thecorrugatedlouverfinsare incorporated.Thiscoolerbodyhasanoil coolerplateandguardas standardequipments.Inaddition,the bracket
mountingis integrated with the oil cooler plate sothatyou can use the oil outlet upside downaswell.
3-Fin 4-Line AW
00-07-0055 4-Fin 5-Line AW
00-07-0008
Thermostat
Only for wet-type clutch cover
02-01-5052
Unusuallyquick response to temperaturechangeisrealized through the useofshape-memoryalloy.
Arelief passage can be secured via bias spring evenwhenthe oil pressure has increased because of thecloggedoilcooler.
Atthe time oflowoil temperatures, oildoesnot flow outtothe oil coolerbecausethethermo unitvalvecloses,but itflowsbackto thefilter
throughthe bypasspassage.When theoiltemperatures risestomore than70degrees,thevalve openstolet theoilflow totheoil cooler.
Thus,the thermounitserves topreventthe overcoolingandto keeptheoilat afixedtemperature.

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‑D4‑ Nov./29/12
Oil catch tank
07-05-0010 09-04-032
(cylinder type) (side cover type)
Tankcapacity:420cc Tankcapacity:550cc
Front fork
０６―０１―０７２８
φ30 Front Fork Set w/Disc brake
(For 10-inch ONLY)
０６―０２―００１５
Top Bridge & Stem
Rear fork
Tubeless wheel (10-inch)
０６―０９―０２１１ (3.5J)
０６―０９―０２１２ (2.5J)
０６―０９―０２１３ (2.75J)
Our original front fork withφ30 inner tube increases the stability of
strokeby damping force generating mechanism of “free-valve” type
andreducestheshockwhenthefrontshocksreboundandcompress.
０６―０１―０７２３
L / R Front Fork Set
Both high rigidity and lightweight, which are both essential for swingarm, have been
achievedwith the well-balancedstructureof our originalpolygonsectionaldesign and
thicknessof thematerial.
Moreover,skillfulbending and buff finish areexcellentandappeal more than others.
For more information, please refer to our parts catalog, or log onto our Web site at
URL http://www.takegawa.co.jp
０６―０３―０１０４ Aluminum Swingarm (12cm-extended)
０６―０３―０１０５ Aluminum Swingarm (16cm-extended)
０６―０３―０１０７ Aluminum Swingarm(16cm-extended・With braced)