Instruction Manual for / Cylinder Kit
Contents
1. N Instruction Manual for 7were2 f Cylinder Kit For exclusive use in Super Head R Item No 70 00 0000 124cc O0 00 0 00 0O 138 cc O Thank you for purchasing one of Takegawa s products O This is a piston and cylinder kit for exclusive use in Super Head R of Takegawa s make You are kindly requested to observe the following in using and installing the kit We have given ceramic composite plating treatment to an aluminum sleeve of the cylinder which has improved durability and abrasion resistance compared with the conventional cast iron sleeves Moreover we have successfully designed the piston clearance to be less and reduced the friction loss The piston is also designed to be light weight and the molybdenum coating is applied to the piston skirt which makes easier the insertion of the piston into the cylinder Please note that in some cases the illustrations and photos may vary from the actual hardware Please read the following before installation Points to notice about sounds After installing this product in some cases a cooling fin in the cylinder may resonate making a sound In this case as a measure fix a damper included in the kit to the cooling fin of the cylinder 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 We shall be held free from any kind of warranty2. end gap at the horizontal position with a thickness gauge lt Top and 2nd If larger than 0 5mm replace them Oil If larger than 0 9mm replace it r 56 000 56 015 59 0000 59 015 55 965 55 985 58 965 58 985 13 002 13 008 mm 12 994 13 000 mm 0 15 0 38 mm 0 20 0 45 mm 0 20 0 70 mm 0 002 0 014 mm 0 05 mm 56 050 0 59 050 0 55 950 0 58 950 0 13 03 mm 12 98 mm 0 50 mm 0 50 mm 0 90 mm 0 12 mm 0 05 mm Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace sE Apr 11 06
3. Oil Intemal diameter of a pin hole Extemal diameter of a piston pin Piston ring end gap size Clearance between cylinder and piston Clearance between piston and pin O 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 lt If larger than 56 05mm at 56 replace it If larger than 59 05mm at 59 replace it Calculate the clearance between a cylinder and a piston O Inspection of Piston O Clear the piston of the remaining carbon residue Fit a piston ring into the piston and measure the clearance between the piston ring and ring groove with a thickness gauge lt If larger than 0 17mm replace it Check the piston for damages O Measure the external diameter of the piston at the specified place at the bottom edge of the piston skirt at the right angle to the piston holes lt If smaller than 55 95mm at 56 replace it If smaller than 58 95mm at 59 replace it O Measure the internal diameter of the piston pin hole If larger than 13 03mm replace it Q Calculate the clearance between the piston and the piston pin O Inspection of Piston Ring Press down a piston ring into the piston with the piston head and measure the clearance of the ring
4. Part Name OY Tat Aurinum cyinder 1 2 pen 3 Piston ring set top and of 1 a Ponp 6 Cyinderihead gask T e evinder apes S Repair Paris Tem No E Gasket kit B 01 13 0103 Po O Piston kit 01 02 0102 Ka 000 02 120 Piston pin circlip set consisting of 6 pcs ILOLO Aluminum cylinder 01 01 0102 13108 KSH T00 for 124 cc sison 13110 KSH T00 for 138 cc 01 05 020 Piston nng set 01 15 023 000 02 102 Piston pin 000 03 048 Cylinder damper B consisting of 10 pcs In a repair parts order with us please quote the Repair Parts Item Nos In some cases however we may not be able to accept your orders for a single item of the assembled unit In this case please order the required parts in the unit of a set SPECIAL PARTS WZN4Se WZA Co Ltd 3 5 16 Nishikiorihigashi Tondabayashi Osaka Japan TEL 81 721 25 1357 FAX 81 721 24 5059 URL htto www takegawa co jp N f Installation Procedures Caution Always be sure to tighten parts to the specified torque using a torque wrench Notice The unskilled or those without proper knowledge are requested not to do the installation work the proper installation work According to the service manual demount the engine from the frame and and disassemble it processing O Setting the cylinder in place with a dowel pin attach it to the crankcase and check for the interference with the crank cases In case there is interference see wh
5. diately and park your motorcyle in a safe place Otherwise the abnormality could lead to accidents Otherwise the continued ride 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 It may cause a fire 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 accidents O Never use parts other than those specified by us Or the unspecified parts may break leading to accidents O Tighten parts securely using a torque wrench to the specified torque Otherwise bolts and nuts may break or come off causing accidents O Since vaporized accumulation of gasoline is quite dangerous work in a well ventilated place It is at the high risk of explosion Be sure to always use premium unleaded petrol Otherwise troubles such as knocking of an engine may cause accidents Please be informed that the product specifications design and prices are subject to change without prior notice Please be informed that we do not accept any complaint filed with us against any technical trouble caused by the combined use of our products with other manufacturers products unspecified by us e Please retain this Instruction Manual for future reference A 271 Apr 11 06 f Kit Contents No
6. e work Otherwise improper work could cause breakage of parts or injuries to yourself As some products and frames have sharp edges or protruding portions please work with utmost care Otherwise you will suffer injuries O Those who are technically unskilled or inexperienced are required not to do the work Improper installation because of insufficient skill and knowledge could lead to parts breakage and subsequently to accidents Always use new pinston pin circlips gaskets packings and the like Worn or damaged ones may cause accidents because of breakage of these parts Before doing work make sure your bike is secure on level ground for the sake of safe work Otherwise your motorcycle could overturn and injure you while you are working 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 O 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 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 leading to accidents O When you notice something abnormal with your motorcycle while riding stop riding imme
7. ere the cylinder interferes with the crankcases the portion After disassembling the crankcases check every component referring to the service manual Caution Do inspection of every component and replacement of consumables with utmost care Measure the deflection of the crank shaft lt If larger than 0 08 mm replace it Inspection of Crank Shaft O Measure the internal diameter at the small end of the con rod lt If larger than 13 05 mm replace it Measure the clearance at the big end of the con rod in the axial direction If larger than 0 4mm replace it C O 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 lt If larger than 0 07mm replace it O 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 f O Installation of this kit requires in some cases engine removal and crankcase disassembly Please prepare and refer to a genuine service manual to do O A crankcase may interfere with a cylinder sleeve depending on individual differences of the crankcases If there is interference the crankcase needs O Referring to the service manual disassemble the crankcases and scrape the interferring part with a file or a hand grinder but bit by bit not to over scrape O In scrap
8. gs and the piston pin and check for jamming of any foreign material by these parts O Attach the piston to the connecting rod with an arrow on the piston in the direction of the exhaust side Second ring chain hole on the crank case with a clean cloth and fix a piston pin Circlip O Remove the cloth used to plug holes Thoroughly degrease the cylinder base of the crankcase and fita dowel pin into the dowel pin hole O Fix a cylinder gasket of the kit into the cylinder base of the crankcase Apply engine oil to the entire inner surface of the aluminum cylinder bore f O stud bolt and attach the cylinder compressing the piston rings Be careful not to move the piston ring gaps out of position Caution Do the work with care not to damage the piston rings Attach the cam chain guide to the cylinder x Installing the chain guide on cylinder the chain guide may not reach at the bottom of the groove In that case you need a modification as the photo shown below to install the chain guide properly Grind here O Install the cylinder head with reference to the instruction manual Apr 11 06 f Reference Value List for Cylinder and Piston Maintenance N Cylinder Distortion Intemal diameter o 56 59 Extemal diamter 7 5 mm from the hem of a on bad 59 7 5 mm from the hem of a skirt Top 2nd
9. ing be careful not to let the cutting chips and shavings into bearings and other parts After the processing of the crankcases clean them N Apr 11 06 C O Securely fix cylinder dampers B O Apply engine oil to grooves for ylinder Installation Procedures Plug the sleeve hole and the cam O Put the aluminum cylinder into the included in the kit between the cylinder cooling fins until they hit a dead end as shown in the figure below This installation is aimed at reducing a resonant sound from a cylinder cooling fin piston rings and with reference to the figure below fix piston rings and arrange the location of piston ring end gaps g O O O z Mark O O Mark O Attach a piston pin circlip to one of two pin holes on the piston Second ring JS l Black a Expander 2 Piston O Attach the piston pin circlip so the ring end gap does not meet with SE Top ring the notch on the piston pin hole a and it should be either on the top F a oo Pi gt Side rails or at the bottom of the piston as ton 9 illustrated in the fig 1 below Expander Pay attention to the cross section as welll O Apply molybdenum solution to the piston pin and the holes on the connecting rod small end End gaps O Air blow the piston rin
10. 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 If you make modifications to the products we shall be held free from any guarantee of the products This kit is for exlusive use in Super Head R of our own make A cylinder included in this kit may interfere with crankcases depending on individual differences of the stock crankcases If there is interference the crankcase needs processing Processing of stock crankcases requires detachment and reinstallation of an engine and separation of crankcases Please do the work correctly referring to HONDA s genuine service manual And the assembly and installation need gaskets etc additionally 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 The following show the envisioned possibility of injuries to human bodies or property damage as a result of disregarding the following MN Caution cautions O This product is designed for exclusive use on the closed course So take note that it is prohibited to drive your motorcycle on a public road after installation of this kit Drive your motorcycle at a legal speed abiding by the laws O Work only when the engine and the muffler are cool Otherwise you will burn yourself Prepare right tools for th
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