Cylinder Kit (124cc) Instruction Manual
Contents
1. SUPERHEAD 4VALVEt R Cylinder Kit 124cc Instruction Manual The ceramic coated cylinder is used HA Cylinder tem No 0 O0 0 0 O0 0 000 V Cylinder O0 00 00 0 0 O O O HA Cylinder We coated the piston with molybdenum O 00 00 0 0 UO O Piston kit O Thank you for purchasing one of our products These piston and cylinder kits are for exclusive use in a motorcycle equipped with a our super head 4valve R Please strictly follow the following instructions in installing and using the kit Please note that in some cases the illustrations and photos may vary from the actual hardware Please read the following before starting the 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 These products are for exclusive in a motorcycle equipped a our super head 4valve R In case these kits are to be used in a stock crankcase the crankcase needs to be processed in the section where a sleeve is to be inserted Consult a technically reliable shop specialized in internal combustion products or motorcycles about the processing Processing of a stock crankcase requires detachment and installation of the engine and separation of the crankcase Please install the products correctly referring to a HONDA s genuine service manual for the above mentioned compatible motorcycles And the assemb2. Always use a torque wrench to screw bolts and nuts tight and securely to the specified torque A Warning Those who are technically unskilled or inexperienced are required not to do the work lt About the use of inner rotor CDI Usable Not Usable Compatible with this kind of base plate Not compatible with this kind of base plate Tap for 88 cc _ ff Tap for 106cc your vehicle Referring to the service manual detach the engine from the frame and disassemble it O Boring of the crankcase is required Please proces the boring of the crankcase referring to the attached sheet Measure the misalignment at two points at the big end of the con rod at right angles to the shaft as shown in the figure on the right If larger than 0 05mm replace it 0 o Check every part A Caution Infallibly inspect every part and check consumable parts for damage and wear What to check Measure the internal diameter at the small end of the con rod lt If larger than 13 03 mm replace it Measure the clearance at the big end of the con rod in the axial direction lt If larger than 0 6mm replace it 000g 000g the Crankshaft Kit pin grooves Measure the misalignment on the journal bearing of the crank shaft Shaft direction If larger than 0 10 mm replace it Bearing direction If larger than 0 05 mm replace it below Installati
3. horizontal position with a thickness gauge lt Top If larger than 0 5mm replace them Oil If larger than 0 9mm replace it Inspection of Cylinder O Check the inside of cylinder for wear and damage O Measure the internal diameters of the cylinder bore at 6 positions at the piston pin angle and at the right angle to it X Y each at upper middle and lower parts of the cylinder bore Treat the largest value as its internal diameter Ceramic coated cylinder Service limit 54 05mm Steel sleeve cylinder _ Service limit 54 10mm yx In case the cylinder wall is beyound the service limits change the cylinder and piston at the same time as a set Check the top surface of the cylinder for scratches and damages O Check the cylinder top surface for distortion with a straight edge and thickness gauge Service limit lf the distortion is more than 0 05 mm replace the cylinder Straight edge Thickness gauge Inspection of Piston O Clear the piston of the remaining carbon residue J Fit a piston ring into the piston and measure the clearance between the piston ring and ring groove with a thickness gauge If larger than 0 17mm replace it Piston ring SS A PPA L A Ath fp ff AAAI ALE 7 Piston ring Piston 7 O Check the piston for damages Measure the external diameter of the piston at the specified place at the bottom edge of the piston skirt at the
4. right angle to the piston pin holes l O In case you judge by the piston After removing the carbon stuck on the piston top take a note of the No stamped on the piston top f ia O Calculate the clearance between the cylinder and the piston Ceramic coated cylinder 0 015 0 04mm Service limit 0 06mm Steel sleeve cylinder 0 03 0 06mm Service limit 0 10mm O Measure the piston pin bore Service limit 12 98 mm HAC GUO H i Order the piston by the No stamped on the piston top C lia Forged piston and cylinder kit a Compact LCD thermo meter non battery type N OPTIONAL PRATS O 01 04 8014 Cylinder kit cylinder piston kit gasket 01 02 6027 Piston kit piston ring pin Forged piston gets more than 0 5 ps than standard piston O 07 04 0035 V cylinder and stick type sensor O 07 04 0037 HA type cylinder and M5 type temp sensor x We have several type of cylinder and sensor configuration check your cylinder type before purchase please refer our catalog O 07 04 0015 V cylinder and stick type sensor 07 04 0033 HA cylinder and M5 type temp sensor x We have several type of cylinder and sensor configuration check your cylinder type before purchase please refer our catalog S
5. h care not to get the ring end gaps out of alignment Second ring l Ring end gap Expander sa ape A PX o Remove the waste cloth used to clog the holes o Degrease well the cylinder base of the crankcase and fix 8 x 12 dowel pins onto the dowel pin holes Silver coated SS Top ring _ we cam chains as shown in the figure below ae Second ring vi E amp DS Side rails Piston pan lt ES Expander o Fix a supplied cylinder gasket into the cylinder Pay attention to the cross section as well J base of the crankcase o Apply molybdenum solution to the piston pin and the holes on the connecting rod small end sealing washer and tighten the guide roller bolt temporarily o Fix a supplied new rubber packing black onto the oil return hole on the cylinder base of the crankcase o Install the piston onto the connecting rod with an arrow on the piston facing the exhaust side o Loosely tighten an original hex bolt which holds the crankcase on the cylinder side o Install the cylinder head with reference to its instruction manual P Feb 22 12 INSPECTION SERVICE LIMITS A Warning The unskilled or those without proper knowledge are requested not to do the installation work O Inspection of Piston Ring Press down a piston ring into the piston with the piston head and measure the clearance of the ring end gap at the
6. likely to cause parts breakage and accidents Before working place the motorcycle on level ground to stabilize its position for safety to avoid the motorcycle overturning O 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 Always start the engine in a well ventilated place and do not start it in an airtight place Otherwise you will suffer from carbon monoxide poisoning 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 and accidents When you notice something abnormal with your motorcycle while riding on the road immediately stop riding and park your motorcycle in a safe place Otherwise the abnormality could lead to accidents O As gasoline is highly flammable never place it close to fire Make sure that nothing flammable is near the gasoline Otherwise there will be a danger of causing fires 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 O Never use any other part than the specified parts Otherwise there is a possibility of parts breakage leading to accidents Always use a torque wrench to tighten bolts and nuts securel
7. ly and installation require gaskets etc which please purchase separately Please be informed that we shall be held harmless against any claim against us whatsoever arising out of use of the products in racing and the like We recommend to install and use an oil cooler for riding at a high outdoor air temperature The following show the envisioned possibility of injuries to human bodies or property damages as a result of disregarding the following cautions O Since this kit is designed and developed for driving in closed course races do not use the kit for running on public roads 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 work in the proper and right way Otherwise improper work could cause breakage of parts or injuries to yourself As some products and frames have sharp pointed or protruding portions please work with greatest care Otherwise you will suffer injuries The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the l Warning 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 Always use new piston pin circlips gaskets and sealings Wear and damage to these parts are
8. on of this kit requires engine removal and crankcase disassembly Do the work correctly strictly following a HONDA genuine service manual for O Measure the deflection of the crank shaft lt If larger than 0 10 mm replace it O Assemble the crankcase referring to the instruction manual or the service manual for o Attach a piston pin clip to either of the piston o Attach the piston pin circlip so the ring end gap does not meet with the notch on the piston pin hole and it should be either on the top or at the bottom of the hole as illustrated in the figure J ee Te Feb 22 12 S o Apply engine oil to the entire inner surface of the aluminum cylinder bore aie SS las o Air blow the piston rings and the piston pin and check for their jamming any foreign material o Apply engine oil to the piston ring grooves Install the piston rings with the printed side facing upward aligning the ring end gaps For details see the photo below o Plug the sleeve hole and the cam chain hole on the crankcase with a clean cloth and fix a piston pin circlip o Attach the piston pin circlip so the ring end gap does not meet with the notch on the piston pin hole and it should be either on the top or at the bottom of the hole as illustrated in the figure below X A ring with a silver coated side is a top ring Do not make mistakes in choosing the right rings Top ring wit
9. r Therefore please always use the special gasket for the cylinder head or cylinder x The Piston Kit 01 02 6024 contains the parts shown in the above enclosed square with the kit No J J Feb 22 12 l N Boring Process to the Crankcase In case you get your crankcase bored outside our factory Joining together the cylinder and the boring processed section of the crankcase process the crankcase little by little until the size measures 56 8 57 0 mm with a crankcase gasket being squeezed X Processing of the crankcase will thin the thinkness of the wall adjoining dowel pin holes So the durability of the crankcase will be reduced resulting in the possible damage of the crankcase in some cases which please take note Gasket OO0 00 Dowel Pin Hole O 00 0010 00 Dowel Pin Hole WOO 00 Caution Since crankcase boring thins the wall thickness and reduces hardness be careful in tightening stud bolts Please take note that in some cases the crankcase may get damaged during use Furthermore please be informed that we shall assume no liability to users for compensation or damages whatsoever of any kind SPECIAL PARTS WN4SeVWYZA 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 s A 3 Feb 22 12 S Installation Procedures Caution
10. y to the specified torque to avoid these parts getting damaged loose and accidents As the accumulation of vaporized gasoline is at the high risk of explosion work in a well ventilated place O Always use high octane gasoline Otherwise problems 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 Please be informed that we shall be held harmless against any claim against us whatsoever arising out of use of the products in racing and the like lt This manual should be retained for future reference S A l Feb 22 12 Kit Contents O V Cylinder 0 0 0 0 0 O U L wp nee 0 eae na gt on OOOO Ca Piston Pin O Sa JOD 01 0007 with wo r IST 5 Piston Pin crips a 2 oos 6 Cyinder Head Gask 1 01 13 8003V E Rubber Packings lac o Done Pins amp 14 a ooo Xx When ordering a repair part of the piston alone prepare the Item No stamped on the piston top surface 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 Xx Composition and gasket shapes of the gasket kit differ depending on the kind of cylinder head and cylinde
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