Instruction Manual for Bore-Up Kit (174.5cc) for HONDA`s CRF150F
Contents
1. Timing hole cap Holding the flywheel loosen a cam sprocket bolt Remove the cam sprocket bolt detach the cam sprocket from the cam shaft and detach the cam sprocket from the cam chain Crank shaft hole cap J TOH Mar 25 05 a a sealing screw O ring and lock the l Remove the cylinder and take off and check two Installation of Cylinder lifter on the cam chain tensioner The lifter will lock if you turn the stopper all the way clockwise Unscrew bolts and washers to remove the cam chain tensioner from the cylinder Removal of Cylinder Head Cylinder and Piston Loosen the nuts washers and bolts on the cylinder head diagonally in a few steps and remove a cylinder head cover Take off and check two dowel pins an oil hole plug and camshaft for abnormality If nothing wrong is found reuse them Oil hole plug Unscrew bolts washers and detach a cam chain tensioner slider from the cylinder head Tensioner slider a OF Remove a cylinder head and take off and check two dowel pins and a cam chain guide for abnormality If nothing wrong is found reuse er l Remove the plugged waste cloth Look into a cam chain hole and check that the cam chain has not come off the sprocket on the crank shaft Degrease the mating surfaces of the crankcase and cylinder with thinner and the like and2. Instruction Manual for Bore Up Kit 174 5cc for HONDA s CRF150F Item No OHOOU oog OUOggd Applicable Model Honda CRF 150F Up to 05 models O Thank you for purchasing one of TAKEGAWA s products Please strictly follow the following instructions in installing and using the products O 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 Features D This is a bore up kit of a cylinder and a piston utilizing a normal cylinder head O A bore diameter has been enlarged from 63 5 mm to 67 0 mm and displacement from 156 8 cc to 174 5 cc DAs this kit goes well with a MUKUNI VM26 carburetor kit and our TAKEGAWA s cam shaft it can be expected that this kit will work to further power up your motorcylcle Please read the following before starting the installation Caution on the fuel This product is so designed to achieve a higher compression ratio than stock engines As for the fuel high octane gasoline should always be used In case regular gasoline is used abnormal combusiton will take place and the engine cannot achieve its original performance Moreover the piston likely will be damaged leading to a serious failure of a motorcycle Before installing this kit make sure that no regular gasoline remains in the fuel tank In case regular gasoline remains in the fuel tank do replace it with high octan
3. attach a dowel pin and cylinder gasket of the kit First clean the inside of the cylinder by degreasing it with thinner and apply engine oil and spread the oil evenly with your fingers Fit the cylinder into the piston little by little with fingers being careful not to move the piston ring end gaps out of place And place the cylinder in the crankcase X After the cylinder has been placed inside the piston pass the cam chain through the cylinder Degrease the upper part of the cylinder and fix the cam chain guide two dowel pins and a cylinder head gasket of the kit Fit the cam chain guide right into the grooves in the cylinder and the crankcase Dowel pins dowel pins for abnormality If nothing wrong is found reuse them Detach a piston pin circlip and pull out the piston pin to demount the piston X Plug the opening on the crankcase with a waste cloth not to get a circlip in it Wipe off gaskets on the surface of the crankcase to mate with a cylinder with a scraper if any Installation of Piston Attach a piston pin circlip to one of the two pin holes on the piston of the kit X Arrange the position of the end gap of the piston pin circlip not to be on the notch of the piston pin hole Circlip Piston Notch end gap Attach piston rings of the kit to the piston Fix both the top and second rings with RN stamped sides facing upwards Be careful not to scratch
4. counter shaft If it is hard to do so insert it while shaking the engine lightly With moderate slack on the drive chain fully tighten the temporarily tightened mounting bolts nuts And fix the drive sprocket Attach a cam chain tensioner s sealing screw Referring to Honda s genuine service manual Make sure that a cam chain tensioner s lifter is locked Attach a gasket of the kit to the cam chain tensioner and install it to the cylinder with two bolts washers Unlock the lifter by turning acam chain tensioner s stopper counterclockwise l Installation of Spark Plug O ring reinstall or connect the removed or disconnected Specified torque parts for tensioner fixing bolt Exhaust pipe 12 N m 1 2 kgf j m for ceiling screw 4 N m 0 4 kgf m Manifold Carburetor Wires to the engine Spark plug cap Clutch cables Crankcase breather tube Seat left and right side covers Fuel tank fuel hose tC ELET ET Co Coy ELEI Rotate the crank shaft clockwise and align again the T mark on the flywheel with the alignment mark on the crankcase cover At this point check that the I mark on the cam sprocket is still aligned with the mating surface of the cylinder head XK S Starting of Engine O0 0 About fuel Always use high octane gasoline Whenever regular gasoline is remaining
5. gasket T 9 Tensioner iter gasket T O Installation Procedures As the engine needs to be removed during the work secure the vehicle on a stand on level safe ground Do the following work only when the engine and the muffler are cool Removal of Engine and Other Parts Removal of Cam Sprocket Rotate the flywheel counterclockwise to be at l TDC Top Dead Center on the compression i ke Thi h i k on th sprocket cover O ring on both intake and stokes Tiismeans ihata marcon ine exhaust sides Completely wipe off gaskets with iywheelis aligned with an alignment mark on nee the crankcase cover and that a rocker arm is a scraper and the like if any remains on the l i l haky cylinder head or cam sprocket cover oose or shaky Referring to Honda s service manual remove Remove tappet hole caps O rings and cam or disconnect the following parts 0 Seat left and right side cover D Fuel tank fuel hose O Wires to the engine O Spark plug cap 0 Clutch cable O Crankcase breather tube 0 Drive sprocket 0 Exhaust pipe O Manifold Carburetor Unscrew bolts nuts which are mounting the engine and then demount the engine from the frame Be careful not to scratch the frame etc Removal of Spark Plug Tappet hole cap Remove a spark plug Remove a timing hole cap and crank shaft hole cap
6. in the fuel tank always replace it with high octane gasoline O O Checking of Every Section oe Check every section for slack in screws nuts a sure that engine oil is remaining in a specified amount Drive the engine in a well ventilated safe place l with great care Leave the engine idling for a l few minutes so engine oil gets circulated all l around the engine Check that there is n Check for any abnormality such as abnormal sounds from the engine oil leak from gaskets and exhaust air leak from a joint on an exhaust pipe Stop the engine and after the engine has become cool enough check every section again for slack in screws nuts etc 0 O About running in For the purpose of shakedown of the piston and cylinder never fail to run in the vehicle for about 100 km at the reduced engine revolutions avoiding the sudden acceleration SPECIAL PARTS UNEX NA 3 5 16 Nishikiorihigashi Tondabayashi Osaka Japan TEL 81 721 25 1357 FAX 81 721 24 5059 URL http www takegawa co jp Sf Mar 25 05
7. airtight place Otherwise you will suffer from carbon monoxide poisoning O When you notice something abnormal with your motorcycle while riding down a road immediately stop riding and park your motorcyle in a safe place Otherwise the abnormaility could lead to an accident O Before doing the work place the motorcycle on level ground to stablize the position of your motorcycle for safety s sake Otherwise your motorcycle could overturn and injure you while you are working O Check or perform maintenance of parts correctly according to the procedures in the instruction manual or a service manual Improper checking or maintenance could lead to an accident 0 If you find damaged parts when checking and performing maintenance of your motorcycle do not use these parts any longer and replace them with new ones The continued use of these damaged parts could lead to an accident Please be informed that because of improvement in performance design changes and cost increase the product specifications and prices are subject to change without prior notice We shall be held harmless against any claim whatsoever arising out of use of the products in racing and the like This manual should be retained for future reference SD Ee Mar 25 05 a O Kit Contents Part Name mo P EE EER 1 1 1 1 I a Piston pin cicips 15 2 7 6 Oyinder head gee f T C7 evinder gasket e Cam sprocket cover
8. e gasoline Safety information on spark plugs Be sure to replace a spark plug with a hot type spark plug DPR9EA 9 NGk or the one with a higher thermal value Determine the heat value of a spark plug depending on how much it is burnt O We do not take any responsibility for any accident or damage whatsoever arising from the use of the products not in conformity with the instructions in the manual O 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 0 You are kindly requested not to contact us about the combination of our products with other manufacturers O This kit is designed for exclusive use in the above mentioned applicable model name This kit cannot be mounted on other types of motorcycles 0 Installation of this kit requires engine removal Please strictly follow HONDA s genuine service manual for your vehicle to do the work correctly O Prepare right tools to do the work strictly following the installation procedures with great caution Besides this instruction manual as well as HONDA s genuine service manual is prepared for those persons who have basic skills and knowledge Therefore we recommend those who are technichally inexperienced or do not have sufficient tools to ask a technically reliable specialist shop for the work O Never fail to do the shake down O The installaiton of thi
9. g hole cap and a crank shaft hole Tighten up nuts first diagonally in a few steps cap Specified torque Specified torque for cylinder head nut for timing hole cap 27 N m 2 8 kgf m 10 N m 1 0 kgf m for cylinder head bolt for crankshaft hole cap 12 NO m 1 2 kgf m 8 N m 0 8 kgfO m Attach an O ring and a gasket of the kit to the cam sprocket cover and fix them to a cylinder head with two bolts Specified torque 9 N m 0 9 kgfO m Fix the tappet hole cap O ring on both intake and exhaust sides to the cylinder head Specified torque 15 N m 1 5 kgf m Installation of Cam Sprocket Check that a T mark on the flywheel is aligned with an alignment mark on the crankcase cover Fix the cam sprocket to the cam chain aligning an I mark on the cam sprocket with the cylinder head mating surface and insert the c am sprocket into the cam shaft Holding the flywheel attach two bolts Specified torque 12 Ni m 1 2 kgff m Prepare a spark plug and fix it Specified torque 18 N m 1 8 kgf m Replace a spark plug with a hot type spark plug DPR9EA 9 NGK or the one with a higher thermal value Installation of Engine and Other Parts With reference to HONDA s genuine service manual place the engine in the frame with care not to scratch the frame or other parts Then temporarily tighten mounting bolts nuts Insert a drive sprocket already attached with a drive chain into the
10. s product increases the heat release value of the engine set off by the increase in power which is unsuitable for long hours of high load driving O Some of bolts nuts dowel pins and packings will be reused But always replace the severely worn or damaged parts with new ones The following show the envisioned possibility of injuries to human bodies or property damages as a result of disregarding the following cautions O Work only when the engine and the muffler are cool Otherwise you will burn yourself O Prepare right tools for the work Otherwise parts will be damaged or you will suffer injuries 0 Always use a torque wrench to screw bolts and nuts to the specified torque Improper torque could cause these parts to get damaged or fall off 0 As some products and frames have sharp pointed or protruding portions please work with your hands protected Otherwise you will suffer injuries O 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 O Check gaskets and packings carefully for wear or damage Always replace the worn or damaged parts with new ones AN The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the Z4 Warning following cautions 0 Always start the engine in a well ventilated place and do not start it in an
11. the piston or damage Gasket piston rings Piston X Da S9 Top ring EZZ Second ring Side rails Expander Pay attention to cross section as well Guide Apply engine oil to the piston pin of the kit the pin Installation of Cylinder Head hole on the piston and the small end of the connecting rod Then attach the piston to the connecting rod with a A mark on the top surface of the piston pointing to the exhaust side and attach a piston pin circlip of the kit Apply engine oil to the piston rings and check that each ring rotates smoothly Do not align the piston Attach the cam shaft two dowel pins and an ring end gap with the piston pin or 90 degrees to oil hole plug apply liquid gasket to the clamp the piston pin Space the ring end gaps 120 face for a cylinder head cover and install it degrees apart See the figure below with a cam top of cam shaft pointing towards the combustion chamber Mark Degrease the mating surface of the cylinder with thinner Pass the cam chain through the cylinder head and then fix the cylinder head Fix the cam chain tensioner slider to the cylinder head with bolts washers Dowel pins _ Side rails 90 to the pin Oil hole plug l Liquid gasket ey Mar 25 05 ee tighten 4 washers nuts and 5 bolts Attach a timin
Download Pdf Manuals
Related Search