Honda Estart Kit User's Manual
Contents
1. SA aa ity ir o x 13 Parts for clutch assy 13111 ZE0 000 PIN PISTON 11370 HN1 000 COVER COMP STARTER 6 11395 KCY 671_ GASKET L COVER 1 8 90004 GHB 680 BOLT FLANGE 6X28 NSHF 1 9 90004 GHB 700 BOLT FLANGE 6X35 NSHF 1 23 ooo AllCableistWga ea SAH battery y y Od A Soleniod 1 28 Starterbutton Pt doeracerKit y y Od ota2. You may have to pull the wires through the rubber grommet as some stators are a little short It is imperative that there is enough strain relief in the harness Remove the Alternator flywheel and inspect the key to make sure there are no burrs or distortions Check the crank to make sure it s clean and smooth If not sand with Emory cloth It is imperative that there are no high spots or burrs other wise you will experience the sadness of your bike dying due to shavings collecting on the coils from the fly wheel rubbing Now in stall the Shim marked P1 This is the thicker of the two shims follow with the crank adapter Hint Rotate motor so key is facing up Crank adapter Tap the crank adapter with a soft mallet to help set it in place If you have a dial indicator it would be a good time to check the run out Install the Joeracer key in the adapter making sure that it is sitting flush and snug with no burrs folds spindles or mutilations Next install the needle bearing over the adapter making sure to grease well q E Now install part 3 from the clutch assembly sketch paying attention to the correct direction the gear is in stalled The thin shim goes in the pocket of the gear facing out Now per the picture carefully install the clutch bearing assembly in the hub part 5 in to part 4 and then in stall over the large gear assembly part 3 Note the position of ft the key and the drive pins Make sure ev
3. the battery mount and air box mod But before we do that Knowing that the bike runs replace the stock CDI with the Dynatek box Now pull out the spark plug and make sure we got spark lf that s cool then follow the pictures forthwith shows Cut the top of the air box out being careful to not cut out the mount bolt Follow the frame as close as possible This is required to provide space for air for the motor the battery takes away You may want to take off the filter and put a rag in the intake Now locate the battery and battery mount and place in the air box so as the battery does not interfere with removing the air filter and so it just barley sticks up to the frame rails Mark the inner fender with a scribe Next drill two holes for either a 5 26 rivet or a 10 32 screw in the middle of the brace Drill two matching holes in the inner fender and fasten with either the rivets or screws use washers on both sides If you use screws use button heads If you use rivets use the big head type with backing washers Use the straps to tie down the battery Note The new battery box has two legs as opposed to an angle bracket The rest of the pictures show the install of the wiring lIl assume you know red is positive Connect the button wires to the solenoid harness Solenoid connector and ground strap which connects to air filter mount bolt This is the positive wire for the Solenoid and the starter cable wh
4. Instructions for the Estart Kit the in y ything and if there are questions call 408 924 01 First off you must be EN with basic hand tools and patient otherwise you might TET a lot of things The only special tool required is a Honda Fly Wheel Puller which can be had at any local bike store Lets begin First put the bike on a Jack or stand and drain all of the oil There is a plug by the alternator side to help drain the left side Remove the seat tank skid plate shift lever and the connectors from the alternator cover You will have to remove the crank vent assembly now I can t legally tell you to throw it as faraway as possible but when they stick and they do it will blow out every seal in your motor Now I can t tell you to replace it but have seen people run a hose up to the air box and put on a little uni filter Keep it high up if you forge deep streams Remember cant tell you to do this so if you do its on your on accord Next remove the alternator cover from the motor Pull out the stud that s left in the engine case Now carefully remove the three 8mm screw and 2 8mm screws holding the stator and pick up Hint degreases every thing makes life easier Be aware of how the cable and cable hold downs are situated Now carefully install the stator hopefully you got a 200 watt version and pick up in the new cover use locktite on the screws just a little please Bend the cable tabs a bit to make sure it does not rub
5. erything rotates freely and apply a libbrial amount of motor oil At this point the clutch will only rotate freely in one direction In stall the second shim part 9 from the clutch assembly sketch Honda part Now carefully align the flywheel to the key you will have to rotate the clutch assembly to align the drive holes with the 2 holes in the flywheel Carefully Tap the flywheel in place If it doesn t want to go on easily you may have to either remove the clutch outer hub and bearing assembly and attach to the flywheel and then assemble to the clutch gear NOTE There are two sets of drive screws included The button heads and the machined socket heads For some flywheels that are of the 98 and earlier the machined socket heads are the only ones that will fit Locktite and torque to 20 ft lbs Note The correct direction of the key is the wide section in horizontal plane The flywheel should be attached to the drive clutch plate The button heads go through the flywheel and attach the in the plate The socket heads are a pin drive where they float The upper pictures show the drive pins socket heads installed prior to the flywheel installation This may not be possible on all bikes the button heads would go on after the flywheel is installed We no longer use the machined socket head screws The button heads should be installed last after the flywheel is torgued down and the assembly Is rotates to center the clutch Through
6. ich goes to the solenoid post 10 This is what it should look like when you getting close The short cable goes from the battery positive to the solenoid the starter cable is on the other post All done 11 Well What are you waiting for start your engine Some advice Charge the battery fully Crank the motor with the release in to charge the caps in the CDI box and then freshen the fuel charge in the cylinder With the choke on full hit the button for a few seconds then dump the release lever the bike if jetted properly should fire right up The skid plate may need to be bent to clear the case and the shift lever will need to be tweaked bent it by putting it in a vise before the weld In other word dont bent it at the weld it will break Final words and disclaimers legal stuff crap my lawyer made me say This kit has no warranty The CDI has a 1 year box and Honda parts have a 30 day limited warranty This kit is considered an aftermarket performance based add on Please read the instructions carefully and if you re NOT SURE call me Because of the do it your self installation can make no guaranties on the install If you are colorblind challenged can make a black and white harness for you or get a friend to help The failure mode is the needle bearing doesn t get oiled properly or the big bolt didn t get Locktite and the proper torque So again read the instructions carefully 12
7. move them and put them in the engine case Now carefully install the alternator Cover The magnets on the flywheel will want to pull it on so have a good grip If everything is nasty oily greasy clean it NOW You will have to fudge with the starter motor to align it Ok now if everything is in place per the assembly drawing start putting in screws Put in a quart of oil by pouring it through the starter drive cover opening This will ensure proper lubrication of all the new parts Now locate the starter drive housing on the new cover should be obvious install part 7 8 and 2 and the cover with gasket Parts 20 5 24 4 9 8 13 from the alternator cover sketch Locktite and tighten the starter bolt Now is a good time to fill the engine sump with oil and start with the kick starter to make sure there are no funny noises and leaks The clutch assembly will kind of whirr and whine slightly but as the motor warms it should all sound normal Let it run for a good 5 minutes Do NOT REV IT ABOVE THE REQUIRED RPM TO KEEP A COLD MOTOR RUNNING If you do you run the risk of prematurely wearing out the crank adapter and bearing lf every thing is cool then shut it down have a beer and rest The hard part is over and I know you anxious to fire this bike electrically 6 Ok having had lunch or dinner and resting the fun starts won t go in to a lot of text here I ll show pictures Its pretty easy The most complicated part is
8. the two holes in the fly wheel install the button heads and locktite torgued to 20 ft Ibs Now install the 75x12x1 25 mm bolt washer use the original and lock washer and torgue down to 70 ft Ibs no more no less if you do it will distort the crank adapter Don t be afraid to use a good deal of locktite Make sure all of the threads are cleaned with brake clean or carb cleaner Again if you have a dial indicator checks the run out of the inside of the flywheel Next install part 1 and part 6 from the sketch Which is the double gear and corresponding pin Locate the starter motor from your box and the long red cable Install the cable on the connector leaving a little loose to adjust later Now locate the over flow hose s from the carb At the engine case there is a metal rod that holds them in place Remove the screw and rod as that s where the starter bolts to the case From the flywheel side slide the starter and align with the screw hole that you removed the rod from From your pile of old case bolts find a screw about 35 mm 1 25 or so and reinstall the metal rod on top of the screw Unless you are good at guessing the alignment of the starter in relation to the case do not Locktite and tighten as you ll be removing later to do so Run the wire up to the air box area Now is the scary part Be very careful Put the gasket on the engine case with the dowels If the dowels are on the alternator cover case re
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