Instruction Manual for Piston Cylinder Bore
Contents
1. Head gasket c Head side Install a circlip to the other pin hole on the piston NE Cross section surface of the gasket In case the top and second rings of piston rings are not the same install them carefully referring to the illustrations below Remove the rubber from the stock cylinder head and install it to kit s cylinder head Top ring 2 Cylinder Installation lt Remove the rubber from the stock cylinder and install it to kit s cylinder Install the cylinder head as the arrow on the head points downward to the exhaust side Second ring Remove the pluged cloth Fix a cylinder gasket Fix the rings with stamped surfaces facing upwards Apply engine oil to the piston rings the piston pin holes the piston pin and the bearing Loosely tighten the four cylinder head nuts by hand Apply engine oil to the inside surface of the cylinder Align ring s end gap with the locator pin on the piston and instal the piston to the cylinder Working the kick starter several times fully tighten the four nuts diagonally to the specified torque Specified Torque 14 N m 1 4 kgf m Align the end gap with the locator pin CHECK Holding the cylinder by hand t2. N Instruction Manual for Piston Cylinder Bore Up 117 2 cc Kit for GRAND Axis 100 Item Nos 00 00 0000 HOU UU 00L L Piston kit Applicable models and frame Nos YA100 SBOiW YA100W SBO6J 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 read the following instructions before installation Do shakedown more than 100 km at 40 km h or less Besides the accelerator opening must be at 1 2 or less For shakedown driving inject engine oil to the fuel tank with the ratio of gasoline to engine oil at 100 1 Set a main jet of a stock carburetor higher by about 5 to 10 notches Fuel must be supreme unleaded high octane gasoline Determine the heat value of a spark plug depending on how much it is burnt Please always use a resistor spark plug 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 installation and use of this product If you make alterations to the products outside our factor
3. e engine or oil leak in every gasket AOSE Band screw 6 Muffler Installation Loosely tighten two bolts on the cylinder side and two bolts on the stay side Install fan s air shroud with care not to shut the two oil like hoses in and install three screws and a tapping screw Fully tighten the two bolts on the cylinder side at first and then those on the stay side Specified Torque Cylinder side 9 N m 0 9 kgf m Stay side 26 N m 2 6 kgf m Install the spark plug cap lt Connect the vent hose with the air induction in case of YA100W Vent hose E aja 5 Air Clearner Case Installation Insert the connecting tube to the carburetor and fix the clip SPECIAL PARTS 3 5 16 Nishikiorihigashi Tondabayashi Osaka Japan TEL 81 721 25 1357 FAX 81 721 24 5059 URL http www takegawa co jp ha Mar 26 07
4. e the position of your motorcycle 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 O If you find damaged parts when checking and performing maintenance 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 WARNING The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the Please 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 Ae This manual should be retained for future reference ZD ries Mar 26 07 Kit Contents No Pars Name y TO _ Gfinderhead eying o Piston o o Psom o o somp fo o Piston pin crops 0 o Cylinder head oas 0 o Cyin gask 0 o Exhaust pipe gask 0 O mark indicates the contents of a piston kit OD i um COG Installation Procedures Stabilize the vehicle in a level place Unfasten each bolt and remove the rear securely with a center stand luggage rack The installation work must be done only when t
5. he engine and the muffler are cold Disconnect lead wires to the battery unfasten each screw and remove the foot rest board Removal Take off all dirt like the dust and oil on each part as you detach it Keep the removed bolts and nuts in an orderly way so you can recall where to fix them Unfasten each two screws on the right and left side covers 7 S 1 Cover Removal lt Unfasten each screw and remove left and Ze Bie right side cover malls lt Unfasten each screw and remove the front side cover Unfasten two nuts and remove the seat 2 Muffler Removal Disconnect the bent hose from the air induction in the case of Yamaha YA100W Vent hose ny F N 2 Ete Mar 26 07 ee Unfasten each two bolts on the cylinder side 4 Air Shroud Removal Remove one of the circlips and take the and on the stay to remove the muffler Pull out the spark plug cap piston pin out Unfasten three screws and a tapping screw to remove an air shroud on the fan Detach the bearing gt al F Y po Get rid of the remaining gasket chips completely with a scraper or a cutter and take all dirt off by cloth lt Remove two oil line hoses from the air shroud 3 Air Cleaner Case Removal on the cylinder Disconnect the air hose from the carburetor in the case of YA100W Remove a sc
6. o prevent it from moving rotate the fan and move the piston Unless the piston moves smoothly the piston rings may not be attached cor rectly In this case do the cylinder installa tion again Screw the spark plug by hand at first and then fully tighten it Specified Torque 20 N m 2 0 kgf m 4 Mar 26 07 4 Air Shroud Installation Insert the connecting tube into the crankcase 7 Installation of Covers Install a cylinder s air shroud with care not cover and tighten the screw on the band Install the foot rest board by each screw to jam the deflector Fix the air cleaner case along with the guide and and connect battery s lead wire Install the two oil line hoses to the air shroud the collar by a screw Install the front side cover by each screw securely Specified Torque Fix the tapping screws for right and left side 7 NU m 0 7 kgf m covers Connect the air hose with the air cleaner case Install the luggage rack by each bolt in case of YA100W Install the seat by the two nuts Install the right and left side cover malls by each screw 8 Engine Starting Check every section for slacks in screws nuts or the like Make sure that engine oil is remaining ina specified amount or more Drive the engine in a well ventilated safe place with great care and warm up the engine lt Check that there is no abnormal noise from th
7. rew along with a cable guide and a collar lt Loosen a screw on the band of the tube connecting to the crankcase cover Olnstallation 1 Piston Installation Install a circlip to one of two mounting places on the kit s piston Rotate the circlip to check that it is fixed securely meee Band screw lt Remove the air shroud on the cylinder Unfasten a clip of the tube connecting to the carburetor and remove the air cleaner case Be careful not to get any dust in the 5 Removal of Cylinder Head Cylinder and carburetor Piston Remove the spark plug Loosen four nuts diagonally in several steps Place a circlip so its end gap does not and remove the cylinder head meet with the notch on the pin hole Circlip Notch End gap Re move the cylinder Plug the crank case with cloth not to let any foreign material fall into it 3 3 Mar 26 07 Insert the bearing into the con rod and install Wipe the mating surface for the cylinder head them as piston s arrow points downward to the well exhaust side Fix the piston rings Piston rings have a different design on each side Install them in the following direction 3 Cylinder Head Installation After wiping the mating surface well install the head gasket
8. 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 pointed or protruding portions please work with your hands protected Otherwise you will suffer injuries O 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 improper attachment of parts may cause parts to come off Always use new gaskets and packings Besides check carefully those parts to be reused and in case wear or damage is detected on the parts always replace these parts with new ones 1 WARNING following cautions 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 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 stabliz
9. y 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 These products are designed for exclusive use in the above mentioned types of motorcycles and frame numbers only Please take note that these productst cannot be mounted on other types of motorcycles Work correctly referring to YAMAHA s right service manual for the above mentioned machines Item No of a service manual 5FA 28197 JO Item No of a supplemental manual for YA100W 5FA 28197 J5 Do the installation work with great care strictly following the installation procedures Besides this instruction manual as well as YAMAHA s genuine parts service manual is written with those persons in mind who have basic skills and knowledge in tuning Therefore we recommend those who are technichally inexperienced or do not have enough tools to ask a technically reliable specialist shop for the work Some of bolts nuts dowel pins and packings will be reused However be sure to replace worn down or severely damaged ones with new ones This piston kit cannot be used even if a stock cylinder is bored This piston kit is repair parts exclusively for 01 05 4455 CAUTION The following show the envisioned possibility of injuries to human bodies and property damage as a result of disregarding the following cautions O Always try to drive your motorcycle at a legal
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