Instruction Manual for Cylinder Set (124 cc)
Contents
1. win Spork DOCI MCAT Instruction Manual for Cylinder Set 124 cc Exclusively for our Twin Spark Super Head R Item Nos 0 O0 O000 0 Cylinder kit HOU UOU OUUU Piston kit O Thank you for purchasing one of our TAKEGAWA s products O These Piston and Cylinder kits are for exclusive use in motorcycles equipped with our TAKEGAWA made Twin Spark Super Head R In using these kits please strictly observe the following Please note Illustrations and photos may vary from actual hardware Please read the following instructions 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 responsibility or compensation whatsoever for any glitch in parts other than ours if the glitch takes place after the installation and use of this product These Piston and Cylinder kits are for exclusive use in motorcycles equipped with our TAKEGAWA made Twin Spark Super Head R In case this set is to be used in a stock crankcase the crankcase needs to be processed in the section where a sleeve is attached Please contact your specialist shop handling internal conbustion products or a motorcycle shop nearby Processing of a stock crank case requires detachment and installation of the engine and separation of the crank case Please install the products correctly r2. Second ring Pa DaN SD Piston E Side rails Expander Pay attention to the cross section as welll Sep 12 06
3. 6 Nishikiorihigashi Tondabayashi Osaka Japan TEL 81 721 25 1357 FAX 81 721 24 5059 URL http www takegawa co jp 7 A3 Crt 14 10 D Installation Procedures J N Caution Always be sure to tighten parts to the specified torque using a torque wrench A Notice The unskilled or those without proper knowledge are requested not to do the installation work O The following show the products of our own make to which this kit cannot be installed On the use of an old type inner rotar CDI usable unusable one mounting tap Tap for 88 Tap for 106 O Some products involve detachment and installation of an engine and sepration of a crankcase etc Do the installation work infallibly following Honda s genuine parts service manual O Referring to the service manual detach the engine from the frame and disassemble it The installation of this kit entails boring process to a crankcase Please proces the boring of the crankcase referring to the attached sheet After modifications 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 If larger than 0 05mm replace it igs SE Right sidecrankcase Left side crankcase Measure the misalignment on the journal bearing of the crank shaft Shaft direction If larger than 0 10 mm replace it Bearing direction
4. If larger than 0 05 mm replace it Sleeve Interference Cylinder N o Check every part Caution Infallibly inspect every part and check consumable parts for damage and wear Measure the deflection of the crank shaft lt If larger than 0 10 mm replace it What to check Measure the internal diameter at the small end of the con rod lt If larger than 13 03 mm replace it O Measure the clearance at the big end of the con rod in the axial direction lt If larger than 0 6mm replace it a B1 Sep 12 06 O Cylinder Installation Procedures O Attach a piston pin circlip to one O Apply molybdenum solution to the O Fix a new rubber packing black of O Loosely tighten the cam chain of two pin holes on the piston piston pin and the holes on the the kit onto the oil return hole on the guide roller and the cylinder side connecting rod small end TE base of the crankcase bolt 4 O Attach the piston pin circlip so the ring end gap does not meet with _ 2s ET the notch on the piston pin hole and it should be either on the top Install the piston to the connecting l O Apply engine oil to the eie inner or at the bottom of the piston as rod so the IN mark on the piston faces surface of the aluminum cylinder illust
5. There are some parts however for which we are not in a position to accept your order in just the quantity to be used In this case please take them in the quantity packed Xx Composition and gasket shapes of the gasket kit differ depending on the kind of cylinder head and cylinder Therefore please always use the special gasket for the cylinder head or cylinder Xx The Piston Kit 01 02 8241 contains the parts shown in the above enclosed square with the kit No J A2 Qt 14 10 01 04 8224V 124cc cylinder kits Boring of a Crankcase To those who ask other specialist shop than us to do the work Joining the cylinders together process the crankcase little by little until the size is 56 8 57 0 mm with a crankcase gasket placed in between x Processing of the crankcase will thin the thinkness of wall adjoining dowell pin holes So the durability of the crankcase will be reduced resulting in the damage of the crankcase in some cases which please take note Gasket 0 OS Dowel pin hole HOW 00 00 00 000 00 Dowel pin hole Caution O Since crankcase boring thins the wall thickness and reduces hardness be careful in tightening stud bolts O 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 NSW Co Ltd 3 5 1
6. consequently to accidents Always use new piston pin circlips gaskets and packing Wear and damage to these parts are likely to cause parts breakage and accidents Before doing work place the motorcycle on level ground to stablize the position of your motorcycle for safety s sake 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 as they are 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 Before riding always check every section for slack in parts like screws If you find slack ones screw them up securely to the specified torque Or improper torque may cause parts to come off leading to accidents When you notice something abnormal with your motorcycle while riding down a road immediately stop riding and park your motorcyle in a safe place Otherwise the abnormaility could lead to accidents 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 serv
7. eferring to HONDA s genuine parts service manual for the the applicable model numbers of the motorcycles And this assembly requires gaskets etc which please purchase separately This set is for exclusive use in CDI motorcycle but is compatible only with a stock CDI and CDI of our own make 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 damages as a result of disregarding the following cautions O 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 muffler are cool Otherwise you will burn yourself 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 4 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
8. ice 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 screw bolts and nuts tight and securely to the specified torque Otherwise improper torque may result in the breakage or coming off of the bolts and nuts leading to accidents As the accumulation of vaporized gasoline is at the high risk of explosion work in a well ventilated place Always use high octane gasoline Otherwise troubles such as engine knocking may cause accidents 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 J Al t 14 10 A Kit Contents 00 00 0000 o O O No Parts Name J iy Repar Paris Ttem No 2 pen or a 3 Piston ring set top ond oi 1 Samoso 1 ee ET 5 Pison pnr a ES e inder head oas a O o a 7 evinder gasket E COO e Rubber packa black 1 woos o f2 e oen ea 2 S ooroo Ea 0 poi pin a a Ea Please note that in ordering repair parts be sure to quote the Repair Part Item No Otherwise we may not be able to accept your orders
9. rated in the fig 1 below the intake side bore An 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 r O Air blow the piston rings and the ar piston pin and check for jamming of O Plug the sleeve me a the cam any foreign material by these parts chain hole on the crankcase with a x O Insert the aluminum cylinder into the O Apply engine oil to grooves for clean cloth and fix a piston pin stud bolts piston rings and with reference circlip to the figure below fix piston rings and arrange the location of piston pe ring end gaps e eee eLo 7 r gt O Compres M the piston rings install the cylinder with care not to move the piston ring end gaps out Degrease the cylinder base of the of place Their end gaps will not be crankcase and fix 8x12 dowel pins out of place onto the dowel pin holes CAUTION Be careful not to damage the piston rings Remove the cloth used to plug holes X A ring with a silver coated side is a top ring Do not make mistakes in choosing the right rings Top ring eS 0o00 Second ring Expander O Fix a cylinder gasket of the kit into the cylinder base of the crankcase _ ee eee n
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