/ Instruction Manual for Cylinder Set (106cc / SCUT)
Contents
1. US PAT 4 amp 8 St29e707 nstruction Manual for Cylinder Set 106cc SCUT Exclusively for our 4 79ge77 The ceramic coated cylinder is used tem Nop 00 O0 G00 0 Cylinder kit We coated the piston with molybdenum 0 0 0 0 0 000 Piston kit O Thank you for purchasing one of our products O This is a piston and 106cc SCUT cylinder set designed specifically for use with our R Stage D Head The use of SCUT cylinder Kit can soup up your engine to 106cc without changing the crankshaft Cylinder has an oil jet hole which can lubricate and cool the piston and the connecting rod Please note Illustrations and photos may vary from actual hardware Read all instructions before starting the 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 the glitch takes place on the other products than this one after the installation and use of this product This set is exclusively for R Stage D of our TAKEGAWA s manufacture In some cases sounds coming from the cylinder may sound louder than stock It is advisable to install an oil cooler for driving at a high outdoor air temperature Please be informed that we shall be held harmless against any claim against us whatsoever arising out of use of2. O Remove the cloth used to plug holes O Degrease the cylinder base of the crankcase and fix 8x12 dowel pins onto the dowel pin holes ooo Side rail Expander Side rail Oil ring Fix a cylinder gasket of the kit into Piston Exhaustmak the cylinder base of the crankcase B the kit onto the oil return hole on the cylinder base of the crank case guide roller and the cylinder side bolt O Apply engine oil to the entire inner surface of the aluminum cylinder bore Loosely tighten an original hex bolt which holds the crank case on the cylinder side O Install the cylinder head with reference to the instruction manual O Insert the aluminum cylinder into the stud bolts Compressing the piston rings install the cylinder with care not to move the piston ring end gaps out of place Their end gaps will not be out of place CAUTION Be careful not to damage the piston rings m Place the cam chain guide roller on the cam chains Qct 09 10 2
3. 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 O 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 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 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 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 A
4. ishikiorihigashi Tondabayashi Osaka Japan TEL 81 721 25 1357 FAX 81 721 24 5059 URL http www takegawa co jp ye Dec 03 12 l D Installation Procedures J N A 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 Tap for 88 Tap for 106 O Some products involve detachment and installation of an engine and sepration of a crank case 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 O Measure the deflection of the crank shaft lt If larger than 0 10 mm replace it o Check every part Caution Infallibly inspect every part and check consumable parts for damage and wear What to check O 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 O Assemble the crank case referring to the service manual O Measure the misalignment at two points at the big end of the con rod at right angles to the
5. s 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 o A _A1 Dec 03 12 Xx When ordering a repair part of the piston alone prepare the Item No stamped on the piston x Please order repair parts with the Repair Part Item No X The Piston Kit 01 02 0125 contains the parts shown in the above enclosed square with the J Kit Contents 0 0 0 0 0 0 O DO 0 0 0 0 0 uN 0 0 0 0 0 uN ov gov sp OV No Parts Name 0v Repar Parts jem No inipade of Trea Sider ora a 2 Piston Molybdenum coated 1 IS109RSHTOT 3 Piston ring set top off 1 is0I2RASTOO oo a pene p Hooo E TER 6 Cylinder head gask Feiner gta 1 3 0606 8 Rubber packing bec 2 EEC E E E Pte top surface 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 kit No SPECIAL PARTS WNSeVWZA Co Ltd 3 5 16 N
6. shaft as shown in the figure on the right lt If larger than 0 05mm replace it 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 A B 1 Cct 09 10 f I 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 Cylinder Installation Procedures of two pin holes on the piston piston pin and the holes on the connecting rod small end 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 piston as illustrated in the fig 1 below Install the piston to the connecting rod so the IN mark on the piston faces the intake ee Piston Notch in the piston hole Circlip ring end gap O Plug the Reeve fiole eT the cam chain hole on the crank case with a clean cloth and fix a piston pin circlip 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
7. 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 shows 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 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
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