Cylinder Kit (148cc / SCUT) Instruction Manual
Contents
1. SUPERHEAD 4VALVE R Cylinder Kit 148cc SCUT Instruction Manual Ceramic coated cylinder ltem No 00 00 0000 Cylinder kit Molybdenum coated piston 00 0 0 0 0 000 Piston kit D Thank you for purchasing one of our products Fitfor Takegawa Complete Engine O This product includes a piston and a cylinder 148cc SCUT for exclusive use with Engine No 4SM 10001 0 our super head 4valve R By replacing with our new crankshaft and the SCUT Cylinder Kit 01 04 8307 the 4SMS 00001 cylinder will be bored to 148cc 4SMP 10001 Please strictly follow the instruction to install this kit Please note Illustrations and photos may vary from the actual hardware Cauti on Can use with special crankcase only please check engine serial number below Engine No 4SM 10001 10284 4SMS 00001 4SMP 10001 0 An engine No is stamped here Please read the following instructions before installation This kit is for exclusive use with our crankshaft 01 10 0092 01 10 0093 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 this2. motorcycle overturning 0 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 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 0 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 O 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 0 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 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 an accident O Never use any other part than the specified parts Otherwise there is a possibility of parts breakage leading to accidents 0 Always use a torque wrench to tighten bolts and nuts securely to the specified torque to avoid these parts getting damaged loose and accidents 0 As the accumulation of vaporized gasoline is at the high risk of explosi
3. on work in a well ventilated place 0 Always use high octane gasoline Otherwise problems such as engine knocking may cause accidents A l Nov 17 11 la N Please be informed that the product specifications design and prices are subject to change without prior notice We shall be held free from any guarantee whatsoever of any trouble caused by the combined use of our products with parts not specified by us This manual should be retained for future reference O Kit Contents 00 00 0000 Item No stamped here i amp Oo Oo No Pats Narre Oy Repar Pars Temi No i packs of T30IT590TO0 C5 Piston pin creip f 2 jocorose TS 6 Cyirder head gasket 1 00 01 0269 8 Rubber sealing be 1 oeme ooro EEE 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 x The Piston Kit 01 02 6030 contains the parts shown in the above enclosed square with the kit No SPECIAL PARTS WALSIN 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 i A 2 Nv 17 11 a O Installation Procedures gt Cau
4. product In some cases noise coming from the cylinder may sound louder than stock We recommend to install and use an oil cooler for riding at a high outdoor air temperature As some products and frames have sharp edges or protruding portions work with your hands protected to avoid injuries The following show the envisioned possibility of injuries to human bodies or property damage as a result of disregarding the following cautions D Since this kit is designed and developed for driving in closed races do not use the kit for running on public roads O Work only when the engine and the exhaust system are cool to avoid burns O Prepare appropriate tools and work properly to avoid the breakage of parts or injuries O As some products and frames have sharp pointed or protruding portions please work with greatest care 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 due to unskilled technique or lack of knowledge could lead to parts breakage and consequently to accidents 0 Always use new piston pin circlips gaskets and sealings Wear and damage to these parts are likely to cause parts breakage and accidents 0O Before working place the motorcycle on level ground to stabilize its position for safety to avoid the
5. t the bottom of the piston as illustrated in the fig 1 below O Install the piston to the connecting l rod so the IN mark on the piston faces l the intake side If you find it hard to put in the pin put it in slowly with a marking pen or the like Never hit it in O Place the cam chain guide roller on the cam chains Wad O Apply engine oil to the entire inner surface of the aluminum cylinder bore Circlip ring end gap O Plug the sleeve hole and the cam chain hole on the crankcase with a clean cloth and fix a piston pin circlip OAir 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 l 4a and arrange the location of piston ring end gaps i Notch in the pist n hole O Install the cam chain guide roller with a sealing washer and tighten the guide roller bolt temporarily O Insert the aluminum cylinder into the stud bolts O Remove the cloth used to plug holes O Degrease the cylinder base of the crankcase and fix 8 x 12 dowel pins l onto the dowel pin holes O Loosely tighten an original hex bolt which holds the crankcase on the cylinder side O Install the cylinder head with reference to the instruction manual J B 1 Nw 17 1
6. tion Always be sure to tighten parts to the specified torque using a torque wrench A Warning The unskilled or those without proper knowledge are requested not to do the installation work O Some products involve detachment and installation of an engine and separation of a crankcase etc Read service manual before install O Referring to the service manual detach the engine from the frame and disassemble it o Check every part A Caution Infallibly inspect every part and check consumable parts for damage and wear O Cylinder Installation Procedures O Attach the piston circlip on the right l O Apply molybdenum solution to the l O Fix a cylinder gasket of the kit into Compressing the piston rings with the stamped arrow in the piston pin and the holes on the the cylinder base of the crankcase install the cylinder with care not lower part wilaiaaggerton Is connecting rod small end to move the piston ring end gaps viewed from the above out of place Their end gaps will not be out of place A Caution Be careful not to damage the piston rings O Fix a new rubber packing black of the kit onto the oil return hole on the cylinder base of the crankcase Stamped arrow Be sure to install the circlip in the direction as shown in the above figure OAttach the piston pin circlip so the ring end gap does not meet with l the notch on the piston pin hole and it should be either on the top or a
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