Instruction Manual for Stroke
Contents
1. Attach kit s gasket to the crankcase and install the right side crankcase O After applying a little Alumi Special to the threaded portion of the crankcase bolts install the bolts onto the crankcase and tighten them diagonally to the specified torque CAUTION Be sure to tighten to the specified torque T 10N m 1 0kgf m Being careful of the direction of the gear shift drum washer tighten it to the specified torque with a hex bolt and attach a rubber plug CAUTION Be sure to tighten to the specified torque 12N m 1 2kgf m T Feb 22 06 Flatten the surface by cutting off O After applying Alumi Special a little Degrease the tapers on the to the threaded part of the stud bolts attach stud bolts to the crankcase and tighten them to the specified torque Fix the stud bolt B the shorter stud bolt to the clutch side T 10N m 1 0kgf m the hole section of the crankcase gasket and the mating surface of the cylinder Xx Be careful not to get any gasket chips in the crankcase Install the parts on the transmission with reference to the manual for the transmission O Fix the oil filter screen and install Super Oil Pump referring to the instruction manual O Install a clutch with reference to the instruction manual for the relative clutch kit instruction manual and the service Were kit i i it a kits cam chain in2. Instruction Manual for Stroke Up Crank Kit D Stroke 54 mm Applicable Models and Frame Nos 0 o 0 0 0 00L 6V Monkey Gorilla L crank Z50J 1600008 1805927 Monkey O Z50 2000001 1XRSOR AEO3 1000001 Gorilla O Z50J 2500001 CRF50F AEO3 1400001 O 0 0 0 UU OUO Monkey BAJA 0O 20 17000010 i XR7OR DE02 1000001 Monkey R 0 AB22 1000017 CRF70F DE02 1700001 Monkey RT AB22 1007601 I O Thank you for purchasing one of our TAKEGAWA s products Please strictly follow the following instructions in installing and using the products Before fitting the products please be sure to check the contents of the kit Should you have any questions about the products please kindly contact your dealer Please note that in some cases the illustrations and photos may vary from the actual hardware Please read the following 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 This kit is designed for exclusive use in the above mentioned applicable models of motorcycles and frame numbers only Please take note that this kit cannot be mounted on other types of motorcycles Installation of this product requires removal and installation of an engine and disassembly of a crankcase Please prepare HONDA s service manual for an above mentioned app
3. Removal Do the following work manual Referring to the service manual dismount the engine from the frame Referring to the service manual disassemble the engine detach the stator plate and then disassemble the crankcase O Remove the oil pump O After removing the kick starter spindle remove the transmission and the gear shift drum as they are chain tensioner and the guide roller from the crankcase O Remove the stud bolt from the crankcase Installation Procedures Get the boring process done Installation Get the boring process done to the O Clean the crankcase referring to the relative service sheet crankcase referring to the attached O Enlarge the orifice diameter on the right side crankcase referring to the O Install the cam chain guide sprocket and the spindle Apply engine oil to the bearings in the crankcase instruction manual for Super Oil O Install the transmission and the gear shift drum to the left side crankcase with reference to the instruction manual and the service manual for Pump the transmission lt 6V vehicle In the case of a 6V vehicle change spindles from a cam chain spindle to O Install the starter spindle Apply engine oil to the big end of the crank shaft and the bearings Attach the crank shaft onto the crankcase and fix dowel pins into the crankcase
4. gasket 0 aoo 0 Co std bot Along To o_ Stud bole TAY ona 0 Noo 03 049 oe o star bot B hor Co a Sa bole 8 eho o KE o eavy duty cam chan 640 0 oros So 0 ewy cam chain e o o S O Cam chain guide spindle O 14675 035 TOO el Seo Pas Nae Oy Repar Paris No 0 Feda ball bearing O meaa asa g Q E E J zJ Feb 22 06 S Boring of a Crankcase lt To those who ask other specialist shop than us to do the work O 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 10 Dowel pin hole O 00 0010 00 WOU 00 Caution Since crankcase boring thins the wall thickness and reduces hardness be careful in tightening stud bolts 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 WNSeVWYA 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 Z aa Feb 22 06 f
5. improper torque may cause parts to come off Always use new gasket and packing In case you continue using these parts carefully check them for wear or damage and in case wear or NS damage is detected always replace those worn or damaged parts with new ones J 2s Feb 22 06 The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the following cautions 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 When you notice something abnormal with your motorcycle while riding down a road stop riding immediately and park your motorcyle in a safe place Otherwise the abnormaility could lead to an accident Before doing work place the motorcycle on level ground to secure it for safety s sake Otherwise your motorcycle could overturn and injure you while you are working 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 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 an accident O As gasoline is highly flammable never p
6. the cran O Attach O rings to the two spots O Fix a generator plate and tighten the O Fix the woodruff key to the crank In case you use a magnet kit i shaft and install the tensioner roller WwW Ee if flat screws shaft othern than a stock magnet kit fix the magnet following the installation procedures of the magnet kit CAUTION Be sure to tighten to the Install the cylinder following the x Specialized Tools flywheel of the crank shaft and install the flywheel After applying screw locking agent a little to the washers and flange nuts tighten them to the specified torque Con rod stopper Item No 000 01 01 specified torque T 44N m 4 5kgf m Lock nut wrench Item No 000 01 021 for 12 7 mm 1 2 Item No 000 01 022 for 19 5 mm 3 8 cylinder installation procedures Flywheel puller Item No 000 01 031 ti Universal holder Item No 000 01 1002 2 Feb 22 06 f a O Inspection of Crank Shaft Reference Value List for Crank Shaft Maintenance Intemal diameter of con rod at small end 13 0030 13 012mm 13 03mm Clearance between con rod s small end and a pin 0 003 0 018mm 0 035mm Misalignment on con rod s big end longitudinal and transversal direction Qf 0 012mm 0 05mm Side clearance 0 1 0 35mm 0 6mm Free play on the joumal bearings in the direction of shaft es 0 1mm in
7. the direction of bearings 0 05mm Crank shaft deflection 0 1mm O Check the crank shaft for damages on the flywheel mounting surface If there is a damage replace the flywheel and the crank shaft O Measure the internal diameter at the small end of the con rod If larger than 13 03 mm replace it O Measure the clearance at the big end of the con rod in the axial direction If larger than 0 6mm replace it hg Measure the misalignment at two points at the big end of the con rod at i right angles to the shaft as shown in the figure on the right lt If larger than 0 05mm 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 Measure the deflection of the crank shaft lt If larger than 0 10 mm replace it Replace Replace Replace Replace Replace Replace Replace Feb 22 N S 8
8. to use a thermometer to control the oil temperatures 007 04 0013 Number of revolutions The upper limt of revolutions varies depending on the installed cam shafts cylinder heads etc Please install a revolution counter to make sure that you drive the engine at revolutions below the upper limit following the instructions for a cam shaft or cylinder head Take note that idling and sudden acceleration in the 1st and the 2nd gear particularly tend to exceed the the upper limit Over revolutions will result in nonsmooth revolutions of the engine not only adversely affecting the engine life but also breaking the engine in the worst case Kit Contents UU U U U DO for 6 V HO U U U D for 12 V HOU UGU UUO Please order repair parts by indicating the Repair Parts No listed below As for the assembled sets in some cases we may not be able to accept your orders for the disassembled components of the above mention assembled unit In this case please order them in units of sets instead of the disassembled component parts UO U0 UU0UU for 6 V UO OU UU OO for 12 V NO Pase OW Repair Pars No Oy Ne Pats Name ly Repair Paris No Oly Co eens ooo o jorwoo a 0 erarkshat comp Joriooo o woont o ono o 0 eodnit key _fooo10 007 To erank case casket _fonsos 0 orank case gasket 1 _frisrcear0_ 1 To Righeside crank case gasket 0 msa035700 0 0 _ Rihtside crank case
9. e be informed that mainly because of improvement in performance design changes and cost increase the product specifications and prices are subject to change without prior notice 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 This manual should be retained for future reference i The following show the envisioned possibility of injuries to human bodies or property damages as a result of disregarding the following i Caution cautions O Since this kit is designed and developed for driving in closed races do not use the kit for running on public roads Always try to 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 the work and do the work in the proper and right way Otherwise improper work could cause breakage of parts or injuries to yourself Always use a torque wrench to screw bolts and nuts tight and securely to the specified torque Improper torque could cause these parts to get damaged or fall off AS some products and frames have sharp edges or protruding portions please work with your hands protected Otherwise you will suffer injuries 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
10. lace it close to fire Make sure that nothing flammable is near the gasoline Since vaporized accumulation of gasoline is at high risk of explosion work in a well ventilated place Cautions before riding On fuel to use Whenever regular gasoline is remaining in the fuel tank always replace it with high octane gasoline On sprocket change The installation of this kit will increase the power of your vehicle So use of a stock sprocket will result in severe wears of parts because of the too low gear not only adversely affecting the engine life but also breaking the engine in the worst case Please get your sprocket high geared Engine parts of our recommendation X This kit is compatible with the engine parts of our recommendations only Therefore please replace the engine parts not recommendated by us with those of our recommendations ae O 0O O ee HU UU UUUU Boreup ki Clutch Regular head bore up kit Clutch Dry type clutch kit Special clutch kit Ignition system Stock C D I Igniton system C D I magnet kit 005 02 082 Hyper C D 0 C D I C D I magnet kit 005 02 031 C D I C D I magnet kit 005 02 051 Ee EE EET 005 02 051 Our products that cannot be used On the use of old type inner rotar C D I Not usable Only one tap for installati Metareven Please never use an old type unusable base plate because the use of it as it is is at high risk of caus ing troubles So change it
11. licable vehicle and work with enough care following the instructions in the service manual Besides this instruction manual as well as HONDA s service manual is prepared for persons who have acquired basic skill and knowledge in tuning We recommend those who are technically inexperienced or without right tools to ask a technically trustworthy specialist shop to do the work 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 If you make alterations to the products we shall be held free from any guarantee of the products You are kindly requested not to contact us about the combination of our products with other manufacturers Always use new bolts nuts dowel pins and packings Never reuse severely worn out or damaged ones Use liquid packings at the specified points only and never use them at unspecified points Otherwise the packings may oppilate oil passages it may break the engine in the worst case Be sure to always use premium unleaded petrol And make sure to check what kind of gasoline is remaining in the fuel tank Whenever regular gasoline is left in the fuel tank always replace it with high octane gasoline Never use this kit on the point ignition system motorcycle Please be informed that what we can safely say is that the ignition system of this kit is c
12. ompatible with ours and stock ignition systems because no data is available with us on the compatibility with other ignition systems Therefore please never use other ignition systems which may cause technical troubles Install an oil filter outside Install an oil cooler whenever necessary Engine oil must be API SF or higher class such as SAE 10W 40 15W 50 which are our recommendations The upper limit of the engine revolutions is 12 000 rpm Please install a tachometer to ensure that you drive at revolutions below 12 000 rpm Change the sprocket with the one which meets the output and specifications This kit cannot perform on its own This kit is only compatible with those engine parts recommended by us So please replace the engine parts not recommended by us with those of our recommendations The installation of this kit entails crankcase boring process For the details please refer to the attached sheet Features The combined use of this kit with the bore up kit of our own make will have a remarkable effect increasing the engine displacement to 124 cc The crank shaft is made light in weight via the introduction of the balance cut aimed at reducing waggling Jump Starting and Sudden Acceleration Idling sudden acceleration and sudden engine braking will put a heavy load on the engine which please note may result in crank shaft damage and engine breakage in the worst case Pleas
13. with the one of our rec ommendations Tap for 88 Tap for 106 About the case of using 5 speed transmission In case you install a 5 speed transmission kit and your kick starter spindle is type A make sure to change the spindle to type B spindle This will improve the efficiency in transmitting the torque at the time of kick start and reduce the load on the gear which will lead to the prevention of gear breakage TypeA Kick starter pinion Kick starter pinion It is necessary to change a kick starter pinion Type B as well at the time of changing the kick starter spindle type B Change it with the right one with the number of teeth to match the transmission kit Please take note that the kick starter pinion Ue pinde kil ere type A is unusable Type B kick starter pinion 23T K 23B Type B kick starter pinion 25T K 25B Ve 6 The ignition systems with faster ignition timing than our settings are excluded So please never use ignition N systems in combination with other manufacturers which may cause technical troubles Others Oil cooler The installation of this product increases the heat release value of the engine set off by the increase in power For a long time and high load running we recommend you to install an oil cooler kit which keeps oil at appropriate temperatures and prevents such troubles as oil film shortage at high temperatures Thermometer It is advisable
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