Instruction Manual for Cam Shaft Kit
Contents
1. O Exhaust pipe muffler a Remove two tappet hole caps a crank shaft hole cap and a timing hole cap c Rotate the crank shaft counterclockwise till a T mark on the flywheel is aligned with the alignment mark on the crankcase cover Then check that it is at TDC Top Dead Center on the i compression stroke where you feel slackness I EAG generator aP Coupler when you move the rocker arm by hand Pulse generator neutral switch 3Pcoupler O Clutch cable 0 Crankcase breather tube O Starter motor cable O Starter motor earth cable 0 Starter motor b Unscrew two bolts on a cam sprocket cover and remove the cam sprocket cover and the gasket b Place a jack or a suitable stand under the engine to support it Remove a cylinder head hanger front engine hanger plate and rear engine mounting bolts nuts and then dismount the engine from the frame Be careful not to give scratches to the frame or other parts d Holding the flywheel tightly loosen two cam sprocket bolts If some gasket chips remain on the surface wipe them out completely with a scraper or the like a HDs Apr 27 06 4 Cam Shaft Installation a Check that the T mark on the flywheel2. Instruction Manual for Cam Shaft Kit Exclusive for Bore Up Item No 00 00 0000 Applicable models Frame Nos SL230 MD33 1000001 0 FTR MC34 1000001 0 XLR125R JD16 1000001 CRF150F Up to 05 models Thank you for purchasing one of our TAKEGAWA s products Please strictly follow the following instructions in installing and using the kit Before fitting the kit please be sure to check the contents of the kit Should you have any questions about the kit please kindly contact your dealer Please read the following instructions before 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 parts other than ours if the glitch takes place after the installation and use of this kit If you make alterations to the product we shall be held free from any guarantee of the kit You are kindly requested not to contact us about the combination of our kit with other manufacturers This kit is designed for exclusive use in vehicles equipped with a TAKEGAWA s bore up piston kit Item Nos 01 02 0911 01 02 0912 01 02 092 This kit is designed for exclusive use in the above mentioned types of motorcycles and frame numbers only Please take note that this kit cannot be mounted on other types of m
3. chain is fit in the timing sprocket of the crank shaft fix the cam chain to the cam sprocket D 32 Apr 27 06 Tighten the cylinder head cover nuts first and then the cylinder head cover bolts Tighten both of them in several steps diagonally Specified torque for cylinder head cover nuts 27 NO m 2 8 kgf m for cylinder head cover bolts 12 NO m 1 2 kgf m Upper surface of cylinder head i Give the crank shaft two turns counterclockwise and align the T mark on the flywheel with the alignment mark on the left side crank case Then check at this point that the engraved lines on the cam sprocket are parallel to the upper surface of the cylinder head 5 Valve Clearance b Install and tighten two tappet hole caps a crank shaft hole cap a timing hole cap and a sealing screw of the cam chain tensioner Torque Tapet hole caps 15 NO m 1 8 kgf m Crank shaft hole cap 8 NO m 0 8 kgf m Timing hole cap 10 NO m 1 0 kgf m Sealing screw 4 NO m 0 4 kgf m g Holding the flywheel tight fully tighten the temporarily tightened two cam sprocket bolts Specified torque 12 NO m 1 2 kgf m Adjusting screw Valve stem a After checking that it is at TDC Top Dead Center on the compression stroke place a thickness gauge between an adjusting screw and a valve stem to measure its valve clearance Valve clearance 0 10 mm for both intake and exhau
4. is aligned oil with the alignment mark on the crankcase cover Apply oil here Oil hole plug Es e Unfasten a sealing screw on the cam chain tensioner and rotate a stopper clockwise to locks Mo tensioner rod e Check that a oil hole plug and two dowel pins are fixed on the cylinder head Apply liquid packing to the mating surface of the cylinder head and fix the cylinder head cover to the cylinder head f Unfasten bolts and nuts on the cylinder head cover by rotating them clockwise in a few steps diagonally and then unfasten sealing washers and cylinder head cover The cam top should point downwards g Detach the cam chain from the cam sprocket to remove it X Be careful not to drop the cam chain into the crankcase Suspend it by a wire or the like b After applying fresh engine oil to the bearings install the cam shaft so that the engraved lines on the cam sprocket are parallel to the mating surfaces of the cylinder head and that the cam top faces toward the combustion chamber f Fix four sealing washers Apply engine oil to the threaded parts and seating faces of four cylinder head cover nuts and tighten them temporarily Then tighten four cylinder head cover bolts temporarily h Remove the loosened two bolts on the cam sprocket Then fix the cam sprocket to a cam shaft of the kit and tighten the two cam sprocket Key bolts temporarily c After checking that the cam
5. to an accident 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 A defective product which we acknowledge is caused by product materials or defect in manufacturing will be repaired or replaced with a new one by us at our expense if and when a claim is filed with us within one 1 month of your purchase However replacing of parts shall be made at users expenses And we shall be held free from responsibility for any defect caused by improper installation or use e You are requested to keep this instruction manual until you discard this product J 21s Apr 27 06 O Kit Contents Parts Name Parts Name Qty Cam shaft Comp fo Cam sprocket cover gasket 0 O Installation Procedures 1 To replace a stock cam shaft the engine need 3 Stock Cam Shaft Removal to be removed from the frame During engine removal and mounting make sure the bike is secure on the sidestand X Work only when the engine and the muffler are cool 2 DEngine Removal a With reference to the service manual remove disconnect the following 0 Seat O Side covers J Fuel tank O Negative terminal on the battery 0 Drive sprocket O Change pedal or change pedal link D Air suction pipe if equipped O0 Carburetor O Spark plug cap O Skid plate SL230
6. e lightly vee neuer z 3 eed d Check for any abnormalily such as abnormal sounds from the engine oil leakage from c Moderately slacking the drive chain tighten the gaskets and slack in the screws and nuts temporarily tightened engine mounting bolts and nuts in the following order Specified torque Rear upper engine mounting bolt nut 49 NO m 5 0 kgf m Rear lower engine mounting bolt nut 49 NO m 5 0 kgf m Front engine hanger plate bolt nut 34 NO m 3 5 kgf m Cylinder head hanger bolt nut 34 NO m 3 5 kgf m d Install a fixing plate of a drive sprocket and tighten two bolts Specified torque 12 NO m 1 2 kgf m e Referring to the service manual install the following parts and and connect the following cables 0 Starter motor O Starter motor earth cable O Starter motor cable O Crankcase breather tube O Clutch cable 0 Pulse generator neutral switch 3P 0 coupler 0 AC generator 3P coupler 0 Exhaust pipe muffler O Skid plate for SL230 Spark plug cap Carburetor Air suction pipe if equipped Change pedal or change pedal link 0 Drive sprocket O Negative terminal on the battery J Fuel tank O Side covers D Seat Y Ca iS Ee SPECIAL PARTS UNIE XNA 3 5 16 Nishikiorihigashi Tondabayashi Osaka Japan TEL 81 721 25 1357 FAX 81 721 24 5059 URL http Awww takegawa co jp X J z5 Apr 27 06
7. otorcycles Installation of this kit requires engine removal and mounting Please perform the installation work correctly with reference to the relevant HONDA genuine parts service manual In installing please work with enough care following the installation procedures Besides this instruction manual as well as a HONDA genuine parts service manual is written for persons who have acquired basic skills and knowledge in tuning We recommend those who are technically unskilled or without enough tools to ask a specialist shop for installation work Some of bolts nuts and dowel pins will be reused However be sure to replace worn down or severely damaged ones with new ones Fuel must be super unleaded gasoline CAUTION The following show the envisioned possibility of injuries to human bodies and property damage as a result of disregarding the following cautions g Please try to drive your motorcycle at legal speed abiding by the laws O Work only when the engine and the muffler are cool Otherwise you will burn yourself O Prepare right tools for the work and do the job correctly Otherwise improper work could cause breakage of parts or injuries to yourself 0 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 Other
8. st Gasket h Rotate the stopper on the cam chain tensioner counterclockwise to unlock the tensioner If you need to adjust the clearance loosen the nut and tighten the adjusting screw Fix the adjusting screw firmly and tighten the nut Specified torque 14 NO m 1 4 kgf m After tightening the nut give the crank shaft two counterclockwise turns to be at TDC again and check if the valve clearance is right If the clear ance is changed adjust it again Repeat the proce dures until the right clearance is obtained ZZ A c Fix a gasket of the kit to the cam sprocket cover and install the cover to the cylinder head Install and tighten two bolts Specified torque 10 NO m 1 0 kgf j m r A 4 Apr 27 06 Va 3 6 Engine Mounting l 7 Engine Starting l a Check each section for slackness in the screws a Set the engine onto the frame with care not to nuts and so on give scratches to the frame and other parts Temporarily tighten the bolts and nuts for rear engine mounting front engine hanger plate and cylinder head hanger b Check that engine oil is in the specified amount c Start the engine in a well ventilated safe place Leave the engine idling for about 5 minutes so b Put the drive sprocket fixed with the drive engine oil gets circulated all around the engine chain into the counter shaft If it is hard to put it in i t it while shaking the engin
9. wise 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 Always use new gaskets and packings Besides check carefully those parts to be reused and in case wear or damage is detected always replace them with new ones The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the following cautions D 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 O 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 secure it for safety s sake Otherwise your motorcycle could overturn 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 0 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
Download Pdf Manuals
Related Search