Takegawa 09-07-2711 User manual

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◎We do not take any responsibility for any accident or damage whatsoever arising from the use of the kit not in conformity with the instructions in the
manual.
◎We shall be held free from any kind of warranty whatsoever of products other than this product if the glitch takes place on the other products than
this one after the installation and use of this product.
◎You are requested not to contact us about the combination of our products with other manufacturers’.
◎Please note that this kit is designed for exclusive use in the above-mentioned models with above mentioned frame numbers but equipped with our
TAKEGAWA-made die-cast clutch cover and that it cannot be mounted on 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.
◎Installation of this kit requires detachment and reinstallation of a tank and other work. We recommend you to refer to the relative HONDA service manual
for the correct work.
◎A ring on the frame harness needs to be either bent or cut off for the installation of this kit. Additionally, a harness wire clip needs to be removed.
However, all these do not affect the safe driving at all.
◎You cannot use this Kit when a standard exhaust system is in use on your motorcycle.
◎Please note that, in some cases, the illustrations and photos may vary from the actual hardware.
Item No.
Fits
：０９−０７−２７１１ 3-fin, silver (for die-cast clutch cover)
：０９−０７−２７１２ 4-fin, silver (for die-cast clutch cover)
：Monkey・Monkey (FI) / BAJA・Gorilla (Models equipped with a die-cast clutch cover)
・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.
Please read the following instructions before installation.
・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.
・As the installaiton of this kit has to do with lubricant agents, be sure to check oil level before starting the engine. If the oil level is low, add the oil.
Moreover, change the oil when the bike already travelled the distance to the point where the oil change is stipulated in the 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
・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
(Mount-on-Frame, Rubber Hose Type)
Instruction Manual for Compact Cool Oil Cooler Kit

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No. Part Name Qty Repair Part Item No. In the units of
Oil cooler COMP. (4-fin Compact Cool) 100-07-0008 1
Oil cooler COMP. (3-fin Compact Cool) 100-07-0055 1
2Oil cooler banjo, M12 215620-000-T20 1
3Oil cooler banjo bolt, M12 200-07-0034 1
4Sealing washer, 14 mm 400-07-0042 5
5Banjo bolt, M10 200-07-0038 1
6Banjoe, M10 (30°)215661-KTK-T00 1
7Sealing washer, 10 mm 400-07-0010 10
8Button head socket cap screw, 6 x 10 200-00-0092 5
9Plain washer, 6 mm 200-00-0086 10
10 Spring washer, 6 mm 200-00-0203 10
11 Oil cooler bracket 115670-165-T10 1
12 Hose clamp 400-00-0052 2
13 Clamp band 100-00-0051 1
14 Ignition coil collar 130511-GAR-T00 1
15 Cap screw, 5 x 50 100-00-0204 5
16 Spring washer, 5 mm 100-00-0043 10
17 Plain washer, 5 mm 100-00-0118 10
18 Insulation lock, 250 mm 300-00-0202 10
19 Oil hose 1000 mm 100-07-0018 1
20 Oil hole plug 119331-GEF-T00 1
21 Hex wrench, 4 mm 1
22 Hex wrench, 5 mm 1
1
１２５
８９
３４６７
１０
１１ １２ １３
１４ １６
１５ １７ １８
１９
２０
２１ ２２
〜Kit Contents〜
※Please note that in ordering repair parts, be sure to quote the Repair Part Item No.
Otherwise, we may not be able to accept your orders.
There are some parts, however, for which we are not in a position to accept your order in just the quantity
to be used. In this case, please take them in the quantity packed.

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６．Place an oil container under the clutch cover,
and remove two oil plug bolts.
※At the time the bolts are removed, the oil in
the oil filter may leak.
(That is why we recommend you to prepare
an oil container.)
５．Secure the oil cooler COMP. to the oil cooler
bracket with a 6 x 10 button head screw and
6mm spring washer. Run the wire harness in
between the oil cooler bracket and the oil
cooler. Please check that the oil cooler COMP.
is horizontal when viewed from the front and
vertical when viewed from the side. When it
is tilting to one side, adjust the position slowly,
holding it. And tighten it up.
NOTE : Be sure to follow the specified torque.
Torque: 14 N･m (1.4 kgf･m)
In the case of the FI Monkey:
The oil cooler and brake wire will interfere with
each other, if this Kit is installed onto a standard
front fork and if nothing is done against the
interference.
Referring to the photo below, remove a standard
cable bracket, and attach the cable with an
included insulation lock.
４．In the case of Monkey BAJA:
Detach the ignition coil, and install it with a collar
in a position so its cord faces rearward, or in
the reverse position.
NOTE : Be sure to follow the specified torque.
Torque: 5 N･m (0.5 kgf･m)
７
８９
６
７．Place one each sealing washer on both sides
of an M10 banjo (30 degrees), and install it
loosely onto a clutch cover. (Install the banjo
with the bent tip facing upward.)
〜Installation Instructions〜
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.02-01-5052).
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
１．Make sure the bike is secure on level ground.
２．Referring to a service manual, remove a seat
and fuel tank.
３．Place the provided oil cooler bracket at the rear
end of a flat surface on the downside of the
frame with the folded-back side of the bracket
facing downward. Secure the frame and the oil
cooler bracket with a clamp band. At this point,
fix the clamp band on the upside of the frame
so its thread part will be under the tank. At the
same time, set the wire and harness to be
under the bracket.
Clamp band
Oil cooler bracket
Button head screw 6 X 10
T=14N・m(1.4kgf・m)
Insulation lock
Oil plug bolt
The bent tip should
face upward
Cable stay

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１３．Add about 40cc of engine oil to a 3-fin oil
cooler, or about 60cc of engine oil to a 4-fin
oil cooler, and then start the engine.
After checking each section for oil leakage,
stop the engine and wait for about one minute.
Then check the level of remaining oil through
an oil pot window in the clutch case cover.
If the level is too low, add engine oil without
fail.
１０．Adjust the direction of the banjos and
fasten the M10 and M12 banjo bolts.
NOTE : Be sure to follow the specified
torque.
For M12 banjo bolt:
Torque: 22.5 N･m (2.3 kgf･m)
For M10 banjo bolt:
Torque: 14 N･m (1.4 kgf･m)
※Caution : Tighten the M12 banjo bolt with a
spanner on the oil cooler header
(the hex portion).
１１．Check every hardware for slack, and
reinstall the fuel tank and seat.
１２．(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.
Thermo unit
８．Put an M12 oil cooler banjo in between two
14mm sealing washers, and attach it to the
oil cooler with an M12 oil cooler banjo bolt
loosely for now.
※The tightening of the bolt, with the sealing
washer being out of recessed portion, causes
the oil to leak.
９．Cut off the oil hose to the proper length.
Slide a hose clamp over the oil hose, being
careful that the hose does not interfere with
other parts. And put the hose into an oil cooler
union and union.
And then, tighten the hose clamp, and join
together hoses with the included two
insulation locks.
※ When a Z-Style exhaust system is installed,
route the hose so it does not interfere with
the exhaust system.
※It is advisable, prior to cutting the hose, to
see where to route the oil hose and how long
it should be.
※Coating slightly of the union with oil makes it
easy to insert the oil hose to the union.
If you have coated the union with oil,
thoroughly wipe off the excess oil that will
squeeze out.
(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
Co.,Ltd.
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.