Instruction Manual for Piston & Cylinder Bore Up Kit Kit, 68cc, for
Contents
1. A Instruction Manual for Piston amp Cylinder Bore Up Kit Kit 68cc for Live Dio Item No 0 00 00 0000 Compatible models and frame Nog Li ve Do SKSOM AF34 1000001 1084598 Live Do ST SKSOM VI AF35 1414329 1458440 SK50M AF34 1200001 1314577 Live DoJ SKSOM VII AF34 3000001 SKSOMT AF34 1500001 1564424 SKSOM VII AF34 3000001 SKSOM AF35 1500001 Live Bo ZX SKSOM Ill AF35 1000001 1080618 SK5OMZ YA AF35 1500001 SKSOMs III AF35 1200001 1266550 SK5OM AF35 1700001 SKSOMI V AF35 1400001 1459965 SKSOM AF35 2000001 SKSOMI YC AF35 1400001 1458875 SKSOM II AF35 2000001 SKSOMA V AF35 1500001 Live Do G sta SKSOM IV AF34 12331451 SKSOM YB AF35 1500001 SKSOMWV IV AF34 2000001 SK5OM YC AF35 1500001 Live Do SR SK5OMR II AF35 1000001 1078328 SKSOMNVV AF35 1700001 SK5OMS II AF35 1200001 1267150 SKSOMW YC AF35 1700001 SKSOMT II AF35 1400001 1459615 SKSOM V AF35 2000001 Read all instructions first before starting the installation O Thank you for purchasing one of our TAKEGAWA made products Please strictly follow the following instructions in installing and using the kit O Before installing the kit please be sure to check the kit contents Should you have any questions about the kit please contact your local motorcycle dealer Do running in more than 100 km at 40 km h or less Besides the accelerator opening must be at 1 2 or less For running in i2. for bolts on the cylinder 18 N m 1 8 kgf Jm for bolts on the stay 27 Nim 2 7 kgf m 0 0 O Installation of covers and the like Install side covers under cover floor steps luggage box and body cover 0 0 0 Starting of engine Check every hardware like screws and nuts for slack Make sure that engine oil is remaining up to the specified level Start the engine in a safe and well ventilated place with enough care Leave the engine idling for about 5 minutes Check for any abnormalily such as abnormal sounds from the engine and oil leakage from gaskets O0 O O About running in Be sure to drive the first 500 km after the installation of the kit keeping the throttle open down at 3 4 or narrower Besides never run at the top speed during this period 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 yy yy Mar 05 07
3. with frame Nos AF34 2000001 and AF35 1500001 and then a fan cover Tools to use Box wrench 10 mm Extension bar small size Ratchet wrench Stubby cross slot screwdriver QO Make sure your bike is secure on a center 0 O0 Removal of muffler stand on flat ground Do the work hereafter only when the engine and muffler are cool O Removal Take off all dirt like the dust and oil on each part as you detach them Keep all the detached bolts and nuts in an orderly manner so you can recall where to reinstall them Remove two cap nuts on the cylinder side i Tool to use Closed wrench 10 12 0 Removal of covers and the like Remove two bolts on 1 the stay Tools to use Box wrench 12 mm Extension bar medium size Ratchet wrench Remove side covers under cover floor steps luggage box and body cover A lt Remove the wires O Slide fuel tank Oo nemeye ot air duct cover Remove four bolts on the fuel tank along with a floor plate Tool to use Closed wrench 10 12 Loosen the bolt Tools to use Box wrench 8 mm Extension bar medium size Ratchet wrench Slide the fuel tank so it does not hinder the work Place a waste cloth between the tank and the frame to protect the frame from getting scratched Loosen a tapping scrw Tool to use Gross slot eC oe large size lt Remove the air duct cover Mar 05
4. 07 O O Removal of cylinder head and cylinder Pull out the piston pin to remove the piston Prize the connecting rubber to detach it O O Removal of shroud on the cylinder Loosen four bolts diagonally in a few steps Tool to use Box wrench 10 mm le Remove the bearing D OS 0 0 O Clean the cylinder mounting Y ht surface Remove the cylinder head If it is hard to remove it hit it lightly with a plastic hammer E 1 Af 7 lt Remove the gasket residues with a cutter knife or scraper In the case of bikes with frame Nos of AF34 2000001 and AF35 1500001 remove two bolts A D Remove the cylinder i h EtA RA gt bf ey 7 rS gt a l c b Clean the cylinder with a waste cloth Remove a negative pressure tube from the shroud Remove the gasket QO Installation O O Attach one of the circlips to the provided piston 0 O Plugging in of waste cloth d lt Cover the crankcase with a waste cloth to protect dust or hardware from getting into the crankcase lt Remove the shroud Tool to use Needl
5. ce L O Installation of cylinder head a Apply oil to bearing Apply oil to the inside of the cylinder O O Installation of piston Install four bolts onto the cylinder head Install the ie akok Put the bearing into the con rod a Mar 05 07 Facing cylinder head Facing cylinder Cross section drawing of cylinder head gasket As illustrated in the above fig install the cylinder head gasket with the convex side toward the cylinder head With a box wrench tighten it loosely for now Tool to use Box wrench 10 mm Cranking the kick starter a few times fully tighten four bolts diagonally in a few steps Tools to use Box wrench 10 mm Ratchet wrench Tightening torque 10 Nim 1 0 kgf m LI O Installation of plug First finger tighten the plug Fully tighten the plug Tools to use Box plug wrench 20 6 mm Ratchet wrench Tightening torque 14 Nim 1 4 kgf m 0 O Installation of cylinder shroud Install the shroud Install two bolts but only one onto bikes of frame Nos AF34 2000001 and AF35 1500001 Tools to use Box wrench 10 mm ly ke Ratchet wrench Tightening torque 10 NEm 1 0 kgfm eB eE Install the negative pressure tube onto the
6. e nose plier Turn the circlip to make sure that it is firmly fixed Place a circlip in a location so its end gap does not meet with the notch ea Notch dG Circlip a Ring end gap 0 O Remove the plug 0 O O Removal of piston Tools to use Box plug wrench 20 6 mm Ratchet wrench lt Remove one of circlips Tool to use Flat tip screwdriver extra fine A Mar 05 07 0 O Install two piston rings with the stamped surfaces facing upward Install the cassis with a piston pin nocking point Mesh the piston ring end gap with the position determining pin of the piston and install the cylinder Install the rings with the stamped surfaces facing upward d Install the piston so the arrow on it points downward O0 O Apply engine oil to hardware ai Double check Holding the cylinder by hand to prevent it from moving rotate the fan and move the piston Unless the piston moves smoothly the piston rings may not be attached correctly In this case do E the cylinder installation again Install a Circlip to another hole Tool to use Long nose plier O O Remove the plugged waste cloth Wipe off thoroughly the dust and oil on the head mounting surfa
7. ill suffer injuries O Before riding always check every hardware like screws for slack If you find slack ones screw them securely up to the specified torque Otherwise improper tightening may cause parts to come off Always use new gaskets and packings And check those parts to be reused for wear and damage If you find worn or damaged parts replace them with new ones O Some of bolts nuts and bearings will be reused However be sure to replace worn down or severely damaged ones with new ones O Check carefully those parts to be re used such as gaskets and packing and in case wear or damage is detected always replace the worn or damaged parts with new ones The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the following warnings Always start the engine in a well ventilated place and do not turn on the engine in an airtight place Otherwise you will suffer from carbon monoxide poisoning When you notice something abnormal with your motorcycle while riding immediately stop riding and park your motorcyle in a safe place to check what has gone wrong Otherwise the abnormality could lead to accidents Before doing work make sure your motorcycle is secure on level ground for safety s sake Otherwise your motorcycle could overturn and injure you while you are working Check or carry out maintenance of your motorcycle correctly according to
8. nject engine oil to the fuel tank in 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 Be sure to always use unleaded high octane petrol A spark plug is included in the kit and determine the heat value of a spark plug depending on how much it is burnt And always use a resistor plug These products cannot provide satisfactory power with a normal CDI unit Please replace the CDI unit with a suitable one In some cases the provided cylinder may interfere because of the individual difference in sizes of the stock crankcases After installing the cylinder to the crankcase check for interference If there is interference never fail to modify the stock crankcase before installation We do not take any responsibility for any accident or damage whatsoever arising from the use of the kit not in conformity with the instructions in the manual We shall be held free from any responsibility or compensation whatsoever for any glitch in the parts other than ours if the glitch takes place after the installation and use of the products If you make modifications to any product of the kit we shall be held free from any guarantee of the product You are requested not to contact us about the combination of our products with other manufacturers Please note that this kit is designed for exclusive use in the above mentioned compatible models and frame numbers only and
9. shroud Install a connecting rubber O Installation of air duct cover Install the air duct cover and tighten the bolt Tools to use Box wrench 8 mm Extension bar medium size Ratchet wrench Tightening torque 10 NEm 1 0 kgfm Install a tapping screw Tool to use Cross slot screwdriver large size Tightening torque 4 Nim 0 4 kgf jm 0 0 O Installation of fan cover Do the wiring to the Gh cover Install the plug cap In the case of bikes of frame Nos AF34 2000001 and AF35 1500001 attach the fan cover with three bolts and tapping screw Tools to use Box wrench 10 mm Extension bar small size Ratchet wrench Stubby cross slot screwdriver Tightening torque for bolt 10 N jm 1 0 kgf jm for bolt 1 N Jm 0 1 kgf m Attach the fuel tube to the fan cover O O Reinstall the fuel tank Put back the fuel tank where it was before and fix it and a floor plate with four bolts Tool to use Closed wrench 10 12 Tightening torque 10 NEm 1 0 kgf jm 0 0O O Installation of muffler Insert a provided exhaust gasket between cylinder and muffler and install the muffler Loosely tighten bolts two each on the cylinder and stay Mar 05 07 First fully tighten two bolts on the cylinder Tools to use Closed wrench 10 12 Box wrench 10 mm Extension bar medium size Ratchet wrench Closed wrench 12 14 Tightening torque
10. that it cannot be mounted on any other models Do the installation work correctly referring to the relative Honda s service manual for the above mentioned compatible models For installation please prepare tools and work with reference to the installation procedures with enough care Besides this instruction manual as well as a HONDA s service manual is prepared with those persons in mind who have basic skills and knowledge 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 and bearings will be reused However be sure to replace worn down or severely damaged ones with new ones AN The following show the envisioned possibility of injuries to human bodies and property damage as a result of disregarding the following CAUTION cautions Please always try to ride a motorcycle at legal speed on the public road abiding by the law O Work only when the engine and muffler are cool Otherwise you will get burned O Do the installation with right tools Otherwise breakage of parts or injuries to you may take place Always use a torque wrench to screw bolts and nuts tight and securely to the specified torque Otherwise these parts may get damaged or fall off resulting in accidents As some products and frames have sharp edges or protruding portions please work with your hands protected Otherwise you w
11. the procedures in the instruction manual or service manual Improper checking or maintenance could lead to accidents 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 wy STe Mer 05 07 No Part Names 1 Cylinder Piston 3 o Piston Tg Piston pin o Piston pin cep 2 o orae head gasket 7 e Praet pipe gasket T o erak pla BRESA T Tools to use for installation Cross slot screw driver medium size Flat tip screwdriver super fine Closed wrench 10 12 Long nose plier Cutter knife or scraper Stubby cross slot screwdriver This screw driver to be used for installing the kit onto bikes with frame Nos AF34 2000001 and AF35 1500001 Box wrench 8 mm Box wrench 10 mm Box wrench 12 mm Box plug wrench 20 6 mm Extension bar medium size Ratchet wrench Others waste cloth 2 stroke oil 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 This manual should be retained for future reference aaa ee ae Mar 05 07 EN Installation Procedures Detach three bolts and tapping screw in the case of bikes
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