Instruction Manual for CYLINDER HEAD Kit
Contents
1. N S01 ICIL LB Instruction Manual for CYLINDER HEAD Kit Item No HOU UU UUUO Compatible engines 1P60 FMJ 1P60 5FMJ O ZS1P50 YMJ O Thank you for purchasing one of our TAKEGAWA products Please strictly follow the instructions to install and use the kit O Before installing the kit please be sure to check the kit contents If you have any questions about the kit please contact your local TAKEGAWA dealer Please note Illustrations and photos may vary from actual hardware Features TAKEGAWA Super Head R is compatible with the above Compatible Chinese engines It is easy to install only replace the cylinder head Both diameters of intake and exhaust valve are designed larger than those of the stock cylinder head IN 28 5 30 EX 23 24 5 Roller bearings are utilized at the shovel portion of valve rocker arms Rocker arm body is forged aluminum It offsets the increased weight with roller bearings As the result all the functions make it possible to provide higher output power in high rom range S 15D camshaft including the specialized decompression adapter gaskets cylinder head cover two types of intake manifolds air from forward or backward and compatible with PE28 and VM26 are included In addition manifold can be installed at various set angles in the area without interference of the frame using the included manifold adapter Please read the following before the installation We shall b2. Head Check the spark plug hole and valve hole for the cracks in the vicinity Check the cylinder head for distortion with a straight edge and thickness gauge lt gt Service limit If the distortion is over 0 05 mm rectify or replace the cylinder head Valve Assembly Install valve spring seats and new valve stem seals Apply molybdenum solution to the sliding surfaces of the valve stems and fit the valves into the valve guides rotating valves slowly with care not to damage the stem seals MaL i Stem seal Crew Valve spring inner C L i 2 Spring seat n gp Valve spring outer SS di ae es rin a wy Valve cotter Owner s Manual To the head attach the valve spring with a narrowly pitch side pointing to the combustion chamber Y Combustion fNarrower chamber Compress the valve spring with a valve spring compressor And apply a thin coat of grease to valve cotters and install them CAUTION Do not compress the valve spring more than necessary Tap lightly the end of valve stems a few times so the valves and cotters fit together well CAUTION Be careful not to damage the valves
3. it with a new one LA Scratch on the seat J A Contacting at a low position Uneven seat width Aer Service limit If the inner diameter is bigger than Contacting at 10 05 mm replace the rocker arm a high position ey Inspection of Rocker Arm Shaft Check the rocker arm shaft for bending scratches and damages Measure the external diameter of the rocker arm shaft Service limit lf the external diameter is smaller than 9 95 mm replace it Service Limit Need to be fixed when the service limit at IN is more than 1 5 mm and when the service limit at EX is more than 1 7 mm If there is a scratch on the valve seat modify the seat If the contact width is wide narrow in a high or low position modify the seat Ask a specialist shop in internal combustion or TAKEGAWA for the modification work Outer diameter of the rocker arm shaft subtracted from the inner diameter of rocker arm is a clearance Service limit If the clearance is bigger than 0 1 mm replace the rocker arm shaft Inspection of Valve Spring Retainer Check the valve spring contact surface of the valve spring retainer for the peeling or damage lf they are damaged be sure to replace them with new ones i Ee Check the valve spring contact 7 surface of the valve spring retainer Inspection of Valve Spring Check the valve springs for scratches and damages Measure the free length of the v
4. al tool Valve spring compressor set of Item No 00 01 1005 Torque unit 1 kgf m 9 80665 N m hewton meter O This mark shows molybdenum solution This solution is a mixture of molybdenum grease and engine oil in the ratio of 1 1 n Apply molybdenum solution or assembly paste to the portions where it is indicated that molyodenum solution needs to be applied NEW O This mark shows those parts to be replaced with every overhaul Do not fail to replace these parts every time they are overhauled O This mark means Alumi Special heat resistant lubricating agent Alumi Special heat resistant lubricating paste and grease which prevent galling from high temperatures and heavy loading and adhesion Purpose good for those parts which get hot like a spark plug and exhaust manifold yx Never apply this to any parts other than the specified parts C Owner s Manual Splitting of Valve Check each valve for bending baking and Inspection of Valve Seat O Compress the valve spring using a valve spring damages Remove carbon sediment in the cylinder head compressor Measure the exterior diameter of the valve stem at combustion chamber and valve ANOTE Never compress it more than neasa the sliding surface of the guide with a micrometer Dissolve red lead primer with oil or the like and apply Special tool Valve spring compressor set of Sei Limit IN 4 42 mm it to the valve face evenly EX 4 4 item No 00 01 1005 an Repla
5. alve springs Outer If the length is below 36 3 replace them Inner If the length is below 33 2 replace them 2E Inspection of Camshaft Checkthe camshaft for scratches cracks and damages Measure the height of each cam lobe below 36 3 below 33 2 Type of casha mke Shaust S 15 cam shaft below 28 87 below 28 87 S 20 cam shaft below 29 05 below 29 05 S 25 cam shaft below 29 3 below 29 0 A type of the camshaft is stamped on the cam flange Figures stamped here 4 Inspection of the Camshaft Bearing Rotate the outer race of the bearings with fingers If the outer race does not rotate smoothly or if it is rickety replace either the ball bearing or cam shaft Bearing Bearing C4 Owner s Manual In the case of automatic decompression camshaft Pull the slide shaft of the camshaft center And compress the spring in the shaft and release the shaft Then check if the slide shaft slides smoothly and slides back to its original position If the slide shaft does not slide smoothly or the tension is not on the spring of the slide shaft change the camshaft Slide shaft Slide the slide shaft and check if the decompression pin moves up and down on the EX side cam If the pin does not move up and down when you slide the shaft or the shaft does not slide because it has become stuck then change the cam shaft Slide shaft Inspection of Cylinder
6. before the inspection and measuring And then blow them with compressed air and dry them well Engine oil for lubricating the camshaft will be supplied through the oil passage in the cylinder head Clean the oil passage before assembling the cylinder head After the disassembly of hardware put a mark on the hardware so they can be reinstalled correctly to their original position Reference Value List for Cylinder Head Maintenance Valve clearance intake 0 05 0 08 mm when cold exhaust 0 05 0 08 mm when cold Cylinder head distortion 0 05mm Replace Inside diameter of valve rocker arm 10 000 10 015mm 10 05mm Replace Outside diameter of rocker arm shaft intake exhaust 980780 9 995mm 9 95mmM Replace Clearance between a rocker arm and a shaft 0 013 0 037mm 0 10mm Replace Inside diameter of valve guide intake 4 500 4 512mm 4 56mm Replace the guide or the head exhaust 4 500 4 512mm 4 57mm Replace the guide or the head Outside diameter of valve stem intake 4 475 4 490mm 4 42mm Replace exhaust 4 460 4 475mm 4 40mm Replace Clearance between a valve stem and a guide intake 0 014 0 037mm 0 09mm Replace the guide or the head AEEY 0 025 0 052mm 0 12mm Replace the guide or the head Valve seat contact width Intake 0 81 1 0mm 1 5mm Modify or replace the head Exhaust 1 00 1 2mm 1 7mm Modify or replace the head Free length of valve spring outer 36 9mm 35 5mm Replace inner 33 59Mm 32mm Replace Speci
7. ce the bent baked or damaged valves with Valve spring compressor new ones Tap the valve once and lightly with a valve punner and rotate it Wipe off the red lead primer on the valve faces and Removal of Valve Cotter Use a magnet to remove the cotter if it does not come Inspection of the Valve Guide tap the valves once and lightly with the valve punner off easily Measure the inner diameter of the valve guide without rotating them and check the contact surfaces Remove first the valve spring compressor and then Service Limit IN 4 56 mm for damages or scratches the following parts EX 4 57 mm Valve spring retainer Replace the valve guide or cylinder head if the valve Valve spring Inner amp Outer guide is scratched or damaged Valve z j Valve a F Inner spring ri Outer spring zs Valve spring retainer f Valve cotter amp Outer diameter of the valve stem subtracted from the NOTE If the valve is damaged at its end do not remove inner diameter of valve guide is a guide clearance it forcibly but rectify the end first before Service Limit IN 0 09 mm removing it EX 0 12 mm Owner s Manual Inspection of Rocker Arm Check the rocker arms for scratches damages and Jamming And check if the bearing rotates smoothly Measure the internal diameter of the rocker arms Unfasten an adjust bolt and check it for scratches If it is scratched change
8. colt Q 8 IT B ood 500 m oo oO No Pat Named OY _ Repair Part No In packs of i Cyinder feed sub a a ao 2 Rocker am COMP o SM SPHTOR S s fodras a CJT a Waive adust screw a ooo CT Salve adust lock ut j ooo a e Cam stopper plate a ao S a 7 Button head socket screw 65 f ooo Sd e Socket cap screw 20 O o oo S oo o Socket cap screw 65 f a ooo oo opeope o poe Car peop cora a peeo 2 jomos o oo a Bpm ns f Cam shaft cover 1 00 01 0249 6 Cynder Read gasket 1 izzsrxieroo 71 EAC CTO KL TOO a inet pine gasket e oo o y a o Exhaust pine gasket oa os a o me mea e a CKO CA intake manifold a o o 2 msa a o a 23 femto e paoa ESETE E e 2 pmo o zown o o peo S a 23 0 Socket cap screw e a ooo y o m HH cap screw ex 23 F Snap ring 6mm Decomp collar 1 Does Not use 1 ooo f e m Manifold adapter 17119 KL1 T00 X 1 See the next page about inner parts assembly and repair parts Please order repair parts with the Repair Part Item No Without the repair part item No we may not be able to provide the correct parts Some parts are only available as a set Please order them with the set number N A A4 Sep 17 10 N Cylinder Head Assembly and repair parts No Part Name Oy Repar Part No In packs of e levhaust eave SSC dC MKT Naive spring outer seat 2 ooroo 2 Nave ste
9. e Caution Keep the specified torque T 15N m 1 5 kgf m O Fix the bolt which is to clamp the oil pipe and tighten it Caution Keep the specified torque T 5 2N m 0 53kgf m J Sep 17 10 Attach the cam chain to the cam O Install the decomp guide weight and O Install the cam shaft chain tensioner O Tighten the adjusting nut to the sprocket When the T mark on the flywheel is aligned with the alignment mark on the crankcase align the alignment mark on the cam sprocket with the alignment mark on the cylinder head O Fasten and tighten the 6x12 socket cap screw on the exhaust side of the cam sprocket to the specified torque NOTE Keep the specified torque Torque 12 NU m 1 2 kgf m P Put the socket cap screw 6x20 into the decomp collar 2 and attach them into the weight Weight Decomp collar 2 Xx Use the shorter collar then decomp collar 2 in sequence referring to the diagram Then tighten them to the specified torque A NOTE Keep the specified torque Torque 12N m 1 2 kgf m Weight Cam sprocket Decomp collar 2 Cap screw 6X20 Decomp guide Cap screw 6X12 Put a 6mm snap ring and a plate through the supplied 3x28 thumb screw and attach them to the tip of the shaft that is included in the camshaft COMP And pull them toward you Thumb
10. e held free and harmless from any and all liabilities or claims for any accidents or damages whatsoever arising from the use of this product not inconformity with the instructions in this manual NOTE This product is compatible with above Compatible engines ONLY Other engines are NOT available The service and repair information contained in this manual is intended for use by whom are qualified and have basic skills and knowledge Any person who attempts service or repairs without the proper experiences tools and equipment are highly recommended to ask speciality shops or professional mechanics We shall be held free from any kind of warranty whatsoever of products other than this product if any defect takes place on the other products than this one after the installation and use of this product TAKEGAWA Co Ltd does not accept returns and or repairs on any parts which have been modified and or installed on a vehicle We do not have any information or service data on the combination of our products and other manufacturer s products The serial No is stamped on the cylinder head This No is occasionally required when ordering the parts Some of the bolts and nuts are reused If they are excessive wore or damaged always use the new ones DO NOT use liquid seals which may jam the oil passages It causes the engine damage in the worst case Always use high octane gasoline ONLY NOTE If the regular gasoline remains
11. engine life but also the mounting angle are different from those of stock breaking the engine in the worst case Please replace the sprocket with the high geared one Upper limit of revolutions Others Redline of rom is set by each camshaft grade Be sure to install tachometer and keep the proper rpm Take note that idling and sudden acceleration in the 1st and the 2nd gears particularly 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 breaking the engine in the worst case Oil cooler The installation of this product increases the heat release value of the engine set off by the increase in power For a long time high load running we recommend you to install an oil cooler kit which keeps oil at appropriate temperatures and prevents such troubles as oil film shortage at high temperatures This kit has two types of intake manifolds facing forward and backward and compatible with PE28 and VM26 and a manifold adapter which makes it possible to install the manifold at the various angles in the area without interference of the frames Both surfaces of manifold adapter has mounting threaded bores with different angles to install manifold There is an optional titanium valve spring retainer for this Super Head which is 30 lighter than steel retainer The surface is treated with a special coating w
12. hose hardness is HV1000 above for added shock resistance and wear resistance Carburetor manifold Optional valve spring retainer Part No 01 12 084 with 2 pieces There are also two mounting holes to install the manifold adapter on the gt _ gt cylinder head a j Furthermore for easy to recognize the point to mount there are marks on N wate mounting surface mounting holes of cylinder head and mounting holes of manifold x Carburetor and insulator are NOT included Purchase our applicable insulators for each carburetor models S 1 2 Sep 17 10 la A Head No Serial No is stamped on cylinder head as identification N You might need this head No when ordering this repair part If you cannot place an order because the repair part No is unknown please place an order like below x Make a note of the number stamped on the left side of the cylinder head Head No KL1 00001 Example of ordering gt Super Head Kit repair part Head No KL1 00001 gt Intake valve Qty 1 Head No stamped here KL1 00 Engine parts of our recommendation X This kit is compatible only with the engine parts of our recommendations Therefore please replace those parts not recommended by us with those parts of our recommendations Recommended Part Clutch Heavy duty clutch kit 02 01 0008 Keihin PE28 carburetor 03 03 027 Mikuni VM26 carbu
13. in the fuel tank be sure to replace it with the high octane gasoline Determine the heat value of a spark plug depending on your setting Use stock ignition system ONLY We do NOT have any data of the combination of other manufacture s products Never combine this product with other than stock ignitions It may cause the problems Installing oil cooler is highly recommended We recommend an engine oil which is API SP class or higher such as SAE 10W 40 15W 50 or equivalent Change the gearing into the suitable one to meet the power or specs This kit is compatible with only the engine parts we recommend Please use our recommended engine parts This product is intended for use ONLY in closed course racing Quick starting and sudden acceleration Idling sudden acceleration and sudden engine braking will put a heavy load on the engine which may result in crank shaft damage and engine breakage in the worst case A Cauti The following show the envisioned possibility of injuries to human bodies and property damage as a result of disregarding the aution following cautions O This product is intended for use ONLY in closed course racing O Do the work only when the engine and muffler are cold at below 35 degrees C to avoid burns Prepare appropriate tools and work properly to avoid the breakage of parts or injuries As some products and frames have sharp edges or protruding portions please work with your hands p
14. ion chamber i As the bearings of the cam shaft Degrease well the upper surface and rocker arm interfere with of the cylinder each other it is necessary to Attach a cylinder head gasket of the move the rocker arm outof kit to the cylinder position and attach the cam yi eal shaft O Install the included cam stopper plate using two button head socket screws 6x15 Align both sides of the cam stopper and the notch of rocker arm shaft Then tighten the screws to the specified torque Caution Keep the specified torque T 8 N m 0 8 kgf m O Slightly eel Alumi Special the heat resistant lubricating agent to threaded portions of the cylinder head stud and head bolt and loosely tighten the head nut and head bolt Align the manning point Align the mounting point O Pull out the rocker arm shaft on the O Set the dowel pin in the dowel pin O Tighten 4 head nuts and 2 head hole on the cylinder Yi bolts diagonally in a few steps to the specified torque in the order indicated in the figure below Caution Keep the specified torque For head bolt T 12 Ni m 1 2 kgf m For head nut T 22N m 2 2 kgf m Reinstall the oil pipe in the same way as it was installed and tighten the banjo bolt to the specified torqu
15. motorcycle stop riding immediately and park your motorcycle in a safe place to avoid an accident Before riding always check such parts as screws for loose If you find loose ones screw them securely up to the specified torque to avoid parts coming off O Check or carry out maintenance of parts correctly according to the procedures in the instruction manual or a service manual Improper checking or maintenance could lead to accidents Fuel must be high octane gasoline Otherwise troubles such as engine knocking may cause accidents 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 instruction manual should be retained for future reference Cautions before riding About cam shaft About fuel There are several kinds of camshaft profiles to meet your riding purpose Whenever regular gasoline is remaining in the fuel tank always replace it You can choose other optional camshafts other than the included with high octane gasoline camshaft in the kit Change of a sprocket The installation of this product will increase the power of your vehicle About exhaust system So use of a normal sprocket will result in severe wears of parts because For 1P60 FMJ and 1P60 5FMJ the diameter of the exhaust flange bolt and of too low gear not only adversely affecting the
16. msed f OSC TH Nave coterSC d A ooo a a a E C E Over sized valve guide for repair In packs of 00 01 0006 Valve guide O 5 x Please order repair parts with the Repair Part Item No Without the repair part item No we may not be able to provide the correct parts Some parts are only available as a set Please order them with the set number SPECIAL PARTS WNAE YNMA Co Ltd 3 5 16 Nishikiorihigashi Tondabayashi Osaka Japan TEL 81 721 25 1357 FAX 81 721 24 5059 URL http www takegawa co jp Y A5 Sep 17 10 f Cylinder Head Installation Procedures O Remove the cylinder head and cam chain tensioner from the engine O Apply an engine oil to the valve adjust screw and install it on the rocker arm Attach the rocker arm to the super head Put the rocker arm for the intake into the tappet hole on the exhaust side of the super head And fix the rocker arm shaft after applying molybdenum solution to it And attach the rocker arm for the exhaust by the same token Fix the special cam shaft Apply engine oil to the bearing intake side And Move the rocker arm on the intake side out of place toward the tappet hole and attach a special cam shaft to the cylinder head And attach the rocker arm on the intake side and rocker arm shaft At this point set the position of the camshaft tops for both intake and exhaust so they face toward the i combust
17. retor 03 03 0321 x To install the carburetor on the included manifold in the kit you need a compatible rubber insulator with above carburetor Rubber insulator for Keihin PE28 carburetor 00 03 0211 Rubber insulator for Mikuni VM26 carburetor 00 03 0210 About optional cam shaft O Optional camshafts which can be installed with this kit are available Choose the camshaft to meet your riding style referring to the below diagram and enjoy riding S 15D cam shaft 01 08 0119 Included in the kit S 20D cam shaft 01 08 0120 S 25D cam shaft 01 08 0121 O About the descriptions of camshafts The bigger the camshaft number of XX YY is the wider the duration is It means to provide higher output power in high range While the smaller their numbers are the narrower the duration is lt means the output power is provided more in low to mid ranges Our kit includes the selected camshaft for each displacement Please choose a suitable camshaft for your riding purpose referring to the camshaft data chart when you purchase our optional camshaft Additionally be careful the engine output power will be changed with specs such as exhaust systems inlet pipe length carburetor diameter compression ratio ignition system ignition timing octane value or with natural phenomenon such as ambient temperature or atmospheric pressure yy A3 Sep 17 10 a f N Kit Contents JUF 1 ririt o oO OO of
18. rotected to avoid injuries Always use new gaskets and seals Worn or damaged parts may cause engine troubles S J Al Sep 17 10 The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the following cautions O Those who are technically unskilled or inexperienced are required not to do the work Improper installation due to unskilled technique or lack of knowledge could lead to parts breakage and consequently to accidents Before working place the motorcycle on level ground to stabilize its position for safety to avoid the motorcycle overturning Always start the engine in a well ventilated place and do not turn the engine on in an airtight place Otherwise you will suffer from carbon monoxide poisoning O As gasoline is highly flammable never place it close to fire Make sure that nothing flammable is near the gasoline It may cause a fire Always use a torque wrench to tighten bolts and nuts securely to the specified torque to avoid these parts getting damaged or loose Never use the parts unspecified by us This may lead to parts breakage and consequent accidents If you find damaged parts when inspecting or performing maintenance of your motorcycle do not use these parts and replace them with new ones The continued use of these damaged parts could lead to accidents O When you notice something abnormal with your
19. rter for a while to circulate the engine oil throughout the engine O Fix a spark plug Slightly apply Alumi Special heat resistant lubricating agent to the threaded portion of the plug and fasten the plug tightly Caution Keep the specified torque Attach the plug cap to the spark plug on the engine Turn on the gasoline cock and ignition to start the engine Warning Be sure to start the engine in a well ventilated place O See if there is anything wrong including strange sounds If nothing wrong is detected do the running in of about 30 to 50 km and then recheck the valve clearance Caution Do the valve clearance rechecking only when the engine and muffler are cold O Wipe out thoroughly the dirt and dust O Do the running in again of 100 to 150 km O After the running in see if there is nothing wrong like strange sounds or blow by gas If something wrong is found disassemble the engine again to check every part of it Warning Never reuse the unusable parts N A B3 Sep 17 10 Owner s Manual A WARNING Since this cylinder head manual is prepared for those who have acquired basic skills and knowledge in tuning those who are technically unskilled or inexperienced are not recommended to do the work After the disassembly of the hardware and a cylinder head clean them with solvent
20. screw e e o o o o o o o o e e ef D F O Attach the snap ring in the shaft groove A NOTE Do not expand the snap ring more than necessary WARNING Always use a NEW snap ring and be sure NOT to reuse it O Remove the cap bolt and spring from the cam chain tensioner and make sure that the pushrod does not protrude with two socket cap screws and tighten them to the specified torque Caution Keep the specified torque T 8 8 N m 0 9 kgf m Caution Keep the specified torque T 5 2 N m 0 53 kgf m O Install the spring and then cap bolt in sequence on the cam chain tensioner Then tighten them to the specified torque Caution Keep the specified torque T 5 2 ND m 0 53 kgf m Cap bolt ers O Check that the T mark on the on the cam sprocket adjusting screw IN 0 05 0 08 When cold EX 0 05 0 08 When cold leave the shaft supplied in the lest the decompression device operate on the exhaust side flywheel is aligned with the T mark Adjust the valve clearance with an E When adjusting the valve clearance O Apply engine oil slightly to an camshaft COMP pulled toward you Caution Keep the specified specified torque O Unscrew the thumb screw O Give the crank shaft two turns counterclockwise to check if the valve clearance changes In case it changes adjust
21. the clearance until it meets the specification O Apply engine oil slightly to an O ring on the cam shaft cover and fasten the sprocket cover to the cylinder head with four socket cap screws to the specified torque A Caution Keep the specified torque T 5 2 N m 0 53 kgf m O ring on the valve adjusting cap and fix the valve adjusting cap with two socket cap screws to the specified torque torque T 5 2 N m 0 53 kgf m Sep 17 10 a Install the cylinder head inlet pipe gasket and then manifold adapter in sequence using socket cap screws 6x35 Caution Keep the specified torque T 10 N j m 1 0 kgf m x Use the manifold adapter as necessary If you do not use the adapter install the manifold with the inlet pipe gasket using the socket cap screws 6x20 O Choose the manifold you use and determine the mounting position Then install the manifold on the manifold adapter putting the inlet pipe gasket between them using the socket cap screws 6x20 Caution Keep the specified torque T 10 N m 1 0 kgf m x If the manifold interferes with the frame after installing the manifold adapter the mounting surface of manifold adapter to fix the cylinder head can be ground to meet your desired size Va vx Engine Starting x Make sure that the ignition and the fuel cock are turning off Continue kicking the sta
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