Instruction Manual for / SCUT Cylinder Kit
Contents
1. PAT No 420351 6 Instruction Manual for CEAT Teena SUPERHEAD 4VALVE SCUT Cylinder Kit For exclusive use with Super Head 4VALVE tem No J 0 O OU Fits Q KSR110 K O Thank you for purchasing one of our products O This is a piston and cylinder kit for exclusive use with our Super Head 4VALVE Please strictly follow the instructions to install and use the kit O This sleeveless cylinder which is made of one piece cast aluminum and ceramic chrome plated has increased the durability and wear resistance more than those of cast iron The piston clearance is reduced so that the friction loss is decreased The piston is designed to be lightweight and molybdenum coating is applied on the skirt portion in order to better break in The stick sensor can be installed on the cylinder With the stick sensor and our optional thermometer you can measure the temperature of cylinder O The cylinder is sleeveless and the skirt portion of piston is shortened in order that the piston moves only inside the cylinder even at BDC So you can get the greater displacement of 178cc over 138cc without any modification of crankcase O 01 04 0121 is modified cylinder fin to fit Down draft carburetors FCRD28 TDMR3z2 Please note Illustrations and photos may vary from actual hardware 178 cc HUUU O 000 178 cc For Keihin FCRD28 TDMR32 Carburetor U O 0 LX11 Points to notice about sounds After installing this product in some2. 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 Please read the following before installation 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 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 If you make modifications to the products we shall be held free from any guarantee of the products This kit is for exclusive use with our Super Head 4VALVE 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 A N Caution cautions O This product is intended for use only in closed course racing or other off road competition and never on public roads or highways Please drive safely and follow the local traffic laws O Work only when the engine and the exhaust system are cool to avoid burns Prepare appropriate tools and work properly to avoid the breakage of parts or injuries AS some products and frames have sharp ed
3. aping be careful not to let the cutting chips and shavings into bearings and other parts After the processing of the crankcases clean them N A May 30 11 O Cylinder Installation Procedures When use on non modified Attach the piston pin circlip so the Attach the piston to the connecting Put the aluminum cylinder into the cylinder ring end gap does not meet with the rod with an arrow on the piston in stud bolt and attach the cylinder notch on the piston pin hole and it the direction of the exhaust side compressing the piston rings should be either on the top or at the Be careful not to move the piston bottom of the piston as illustrated in ring gaps out of position the fig 1 below O Need to be cut about 10mm tip of the fin as shown A Caution Do the work with care not to damage the piston rings 7 NS Notch O Air blow the piston rings and the piston pin and check for jamming of any foreign material by these parts O Apply engine oil to grooves for piston rings and with reference to the figure below fix piston rings and arrange the location of piston ring end gaps clean cloth and fix a piston pin circlip x Please cut only as need to fit carburetor Securely fix cylinder dampers B included in the kit between the cylinder cooling fins until they hit a dead end as shown in the figure below This insta
4. cified in the specification list x Cylinder wall Piston part number 66 986 67 000 gt 13101 KFS TOOR Red paint lt 67 001 67 014 gt 138101 KFS TOOY Yellow paint 67 015 67 030 gt 13101 KFS TOOB Blue paint yx In case the cylinder wall is beyound the service limits change the cylinder and piston at the same time as a Set Q2 Check the top surface of the cylinder for scratches and damages Check the cylinder top surface for distortion with a straight edge and thickness gauge a Service limit If the distortion is more than 0 05 mm replace the cylinder Thickness gauge Inspection of Piston 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 Service limit 0 17mm Piston ring Piston Ye iy 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 right angle to the piston holes Service limit 66 95mm Figure out the clearance between cylinder and piston Inspect that the clearance is within the standard value specified in the specification list If not change the piston with a new one Speitied measure point INSPECTION SERVICE LIMITS Inspection of Piston Ring Measure the internal diameter of the piston pin
5. e that nothing flammable is near the gasoline It may cause a fire 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 Always use a torque wrench to tighten bolts and nuts securely to the specified torque to avoid these parts getting damaged or loose 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 A1 May 30 11 f Kit Contents 0 0 0 0 0 000D 00 00 0 000D UOU OU OUUUU L SUUUUUUUUUUUUU URUNU Me ae Ld ap rear Eae tento Parts Item No _ 1 yin am Lape KFS TOOR Piston 13101 KFS TOOY 13101 KFS TOOB 3 Piston r
6. easure the cylinder by the inspection method described on page C2 and replace the piston with the one with a specified piston part number C3
7. ges or protruding portions work with your hands protected to avoid injuries 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 because of insufficient skill and knowledge could lead to parts breakage and subsequenily to accidents Always use new piston pin circlips gaskets seals and the like Worn or damaged ones may cause accidents because of breakage of these parts 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 turn on the engine in an airtight place Otherwise you will suffer from carbon monoxide poisoning O 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 When you notice something abnormal with your motorcycle stop riding immediately and park your motorcycle in a safe place to avoid an accident O As gasoline is highly flammable never place it close to fire Make sur
8. hole Press down a piston ring into the piston with the If larger than 13 03mm replace it piston head and measure the clearance of the ring end gap at the horizontal position with a thickness gauge Top If larger than 0 5mm replace them Oil If larger than 0 9mm replace it Measure the external diameter of the piston pin Piston pin service limit If it is below 12 98 mm replace the piston pin Calculate the clearance between the piston and the piston pin Supplement A number and an alphabet are stamped on the top and side of the cylinder respectively In case you cannot measure the cylinder wall you can designate the type of the cylinder and order it by the stamped numbers This is limited only to the case where there is no damage or scratch on the cylinder wall 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 13101 KFS T00 O Order the piston by the No stamped on the piston top O In case you judge by the cylinder Take a note of the No stamped on the side of the cylinder ec E iror Kse Tooo Take a note of E the stamped No Piston part number When an Ris stamped 13101 KFS TOOR Red paint When a Y is samped 13101 KFS TOOY Yellow paint When a B is stamped gt 13101 KFS TOOB Blue paint O In case No is not stamped on the cylinder M
9. ing set top of oa foss To O on peste a s Piston pin coris 2 joooroos o o eree aoo a 7 eying iL CT e Cynder apes j 9 ooo o oo There are three sizes of replacement pistons As the clearance of the pistons in this kit is severe you need to carefully inspect the cylinder size to fit When you order piston please place an order with the Repair Parts Item No referring to the owner s manual 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 Benchmark data Bore amp stroke Displacement 67 x 50 6 178 3 cm 12 0 1 SPECIAL PARTS WNSeYWA 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 Va N A A2 May 30 11 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
10. llation is aimed at reducing a resonant sound from Remove the cloth used to plug holes Thoroughly degrease the cylinder base of the crankcase and fit a dowel pin into the dowel pin hole 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 a cylinder cooling fin Yogi O Fix a cylinder gasket of the kit into i a 60 60 a6 Install the dampers between the fins SUA the cylinder base of the crankcase ee aia Grind here gt O Attach a piston pin SIAP to one meea Pomeni of two pin holes on the piston piston pin SS to the piston pin Apply molybdenum solution to the piston pin and the holes on the l O Install the cylinder head with connecting rod small end reference to the instruction manual O Apply engine oil to the entire inner surface of the aluminum cylinder bore May 30 11 INSPECTION SERVICE LIMITS A WARNING Since this cylinder manual is prepared for those who have acquired basic skills and knowledge in tuning those who are technically unskilled or inexperienced are required not to do the work Reference Value List for Cylinder Maintenance Cylinder Dist
11. ortion M 0 05 mm Replace Piston Extemal diamter 3 5 mm from the hem of a skirt ee 66 95 0 Replace pee reset are a pn oe A 13 03 mm Replace Extemal diameter of a piston pin 12 994 13 000 mm 12 98 mm Replace Piston ning end gap size ka 0 50 mm Replace ron A 0 90 mm Replace Clearance between cylinder and piston lt 00050 0 012 mm 0 05 mm Replace Clearance between piston and pin b 0 0020 0 014 mm 0 05 mm Replace O Torque unit 1 kgf m 9 80665 N m newton meter O This mark shows molybdenum solution This solution is a mixture of molybdenum grease and engine oil in the ratio of 1 1 Apply molybdenum solution or assembly paste to the portions where it is indicated that molybdenum solution needs to be applied Qey O This mark shows those parts to be replaced with every overhaul Do not fail to replace these parts every time they are overhauled Engine oil gt mark Apply engine oil where so indicated C INSPECTION SERVICE LIMITS Inspection of Cylinder Check the inside of cylinder for wear and damage 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 If larger than 67 04mm replace it Calculate the clearance between a cylinder and a piston Check that the clearance is within the standard value spe
12. where 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 scr
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