Instruction Manual for High-Compression Forged Piston Kit (φ67)
Contents
1. S Instruction Manual for High Compression Forged Piston Kit 67 temNo QOO OU0 O000 Applicable to CRF150F Up to 05 models 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 O Features O This piston kit is to bore up a stock cylinder by a boring process using a stock cylinder head Besides this kit can be used as repair parts for our product Item No 01 05 0101 OA 67mm forged piston in this kit enlarges the displacement volume from 156 8cc to 174 5cc and the specially designed shape of the piston top increases the compression ratio to 11 5 1 O If used together with out TAKEGAWA s MIKUNI VM26 carburetor kit and or a cam shaft your motorcylce will be rendered more powerful O For Proper Use and Safety s Sake Caution about fuel to use This product is so designed to achieve a higher compression ratio than stock engines As for the fuel high octane gasoline should always be used In case regular gasoline is used abnormal combusiton will take place and the engine cannot achieve its original performance Moreover it is highly likely that the piston will be damaged leading to a serious failure of a motorcycle Before installing make sure2. set the valve clearance at 0 10 mm at both intake and exhaust sides Then holding the adjust screw tighten the lock nut to the specified torque 14N m 1 4kgf m Check the tappet hole cap for the damage on the O ring and check how the cap is fixed and apply engine oil to the O ring Then tighten the tappet hole cap crank shaft hole cap and the timing hole cap to the specified torque of 15N m 1 5kgf m 8ND m 0 8kgf m and 10N m 1 0kgf m respectively O ring on the cam chain tensioner turn it clockwise with a screwdriver Then place a new gasket with the tensioner rod being pulled in and fit the tensioner into the cylinder Tighten a cam chain tensioner socket bolt together with an attached sealing washer l to the specified torque of 12N0 m 1 2kgf0 m Then install and tighten a cam chain tensioner ring screw together with an attached O ring to the specified torque of 4N m 0 4kgf m pou sprocket cover and fix it together with a kits cam sprocket base gasket Install the cam sprocket cover on the cylinder head and tighten bolts to the specified torque 10ND m 1 0kgf0 m 0 OO Check the condition of an O ring of the starter motor apply engine oil to the O ring and fix it Temporarily fix the starter motor with a bolt As an earth cable will be tightened with this bolt together with the said starter motor so fully tighten the bolt when you mount t
3. that no regular gasoline remains in the fuel tank In case regular gasoline is remaining in the fuel tank do replace it with high octane gasoline Caution about a spark plug Be sure to replace a spark plug with a hot type spark plug DPR9EA 9 NGK or the one with a higher thermal value Subsequently choose and use a right spark plug with the right level depending on the degree of burning of the spark plug electrode section O 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 O 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 0 If you make alterations to the product outside our factry we shall be held free from any guarantee of the product 0 You are kindly requested not to contact ue about the combination of our products with other manufacturers O This product is designed for exclusive use in the above mentioned type of motorcycle only Please take note that this product cannot be mounted on other types of motorcycles Installation of this product requires engine removal and mounting Please prepare and refer to a HONDA genuine parts service manual in order to perform installation work properly O Prepare right tools for the work and do the work following the installation procedures Beside
4. e piston to face 0 O Degrease the cylinder fitting plane on the tip Then fix a wrist pin holes end gap must not be placed in the same X Side rails a Pin at right angles GS fop ring WZ gt Becond ring i 5 r s le Side rails Expander Cross section diagram the exhause side And apply engine oil to the wrist pin pin hole in the piston and crank shaft Fix the kit s wrist pin clips do not let their end gaps meet with the notches on the wrist pin 0 O Apply engine oil to the piston rings and check that the rings rotate smoothly Every piston ring direction as the wrist pin or at right angles to the wrist pin and space the ring end gaps 120 degrees apart See the figure on the right crank case and fix dowel pins and a kits inner side of the cylinder and install the with fingers 0 O Degrease cylinder s mating surface and attach a chain guide dowel pins and kit s cylinder head gasket and then install the cylinder head Attach washers and install and tighten 10NQ m 1 0kgf m 0 ORemove a crank shaft hole cap and timing hole cap Rotate the crank shaft timing hole cap at an alignment mark and check that it is at compression top dead center cylinder gasket Apply engine oil to the entire cylinder while compressing the piston rings cylinder head bolts to the specified torque of counterclockwise and set a T mark on
5. he enigne to the body Apply engine oil to the starter reduction l gear and the sliding surface of the gear shaft and intstall them Then check the condition of the O ring install a starter reduction gear cover coated with engine oil and tighten the bolt to the specified torque of 10N m 1 0kgf j m O O With reference to the service manual mount the engine to the body Start the engine in a safe place with great care and check that there is no abnormal sound from the engine SPECIAL PARTS UNEX NA 3 5 16 Nishikiorihigashi Tondabayashi Osaka Japan TEL 81 721 25 1357 FAX 81 721 24 5059 URL http Awww takegawa co jp wy Jul 28 06
6. ns 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 improper torque may cause parts to come off Before doing work place the motorcycle on level ground to stablize the position of your motorcycle for safety s sake Otherwise your motorcycle could falldown and injure you while you are working The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the WARNINGS following cautions Always drive the engine in a well ventilated place and do not switch 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 Please be informed that mainly because of improvement in performance design changes and cost increase product specifications and prices are subject to change without prior notice A defective product which we acknowledge is caused by product materials or defect in manufacturing will be repaired or replaced with a new one if and when a claim is filed with us within one 1 month of your purchase However replacing of parts shall be made at
7. s this instruction manual as well as a HONDA genuine parts service manual is prepared for persons who have acquired basic skills and knowledge in tuning We recommend those who are technically inexperienced or without enough tools to contact a technically reliable specialist shop for the work O Carry out shakedown without fail O The installation of this product increases the heat release value of the engine caused by the increase in power Therefore this is inadequate for the long time high load driving 0 Bolts nuts and dowel pins will be reused However be sure to replace worn down or severely damaged ones with new ones 0 Installation of this kit requires boring processing of a stock cylinder Please contact a technically reliable specialist shop handling internal combustion oe a motorcycle specialist shop nearby or contact us direct The following show the envisioned possibility of injuries to human bodies and property loss as a result of disregarding the following CAUTION f cautions Work only when the engine and the muffler are cool Otherwise you will burn 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 Always replace a damaged or worn down sealing washer gasket oe O ring with ehw new one Oherwise oil will leak causing a trouble DAs some products and frames have sharp pointed or protruding portio
8. the flywheel which can be seen through the y 2 Jul 28 06 an Apply engine oil to the bearings of the camshaft and fix the camshaft to the cylinderhead with the cam top facing downward After attaching the cam chain to the cam sprocket align the mark off lines on the cam sprocket with the mating surface of the cylinder head cover and tighten cam sprocket bolts to the specified torque of 12N m 1 2kgf m 0 D Attach dowel pins and an oil hole plug to the cylinder head apply liquid gasketl to the mating surface of the cylinder head cover and install it to the cylinder head 0 0 O Apply engine oil to the threaded part and seating face of cylinder head cover nuts And attach new 8mm sealing washers and tighten them Attach cylinder head cover bolts and washers and fix cylinder head bolts Tighten the following parts to the following specified torque Cylinder head side cover nuts 27N Q m 2 8kgf m Cylinder head cover bolts 12N0 m 1 2kgf m O Tighten cylinder head cover nuts first Tighten cylinder head cover nuts and cylinder head cover bolts diagonally in a few steps l 0 OO Set a T mark on the flywheel which can be O O OCheck the condition of an O ring of the me seen through the timing hole cap at an alignment mark and check that it is at compression top dead center Insert a thickness gauge between the valve adjust screw and the valve stem to
9. users expenses And we shall be held free from responsibility for any defect caused by improper installation or use o You are requested to keep this instruction manual until you discard this product J 1 Jul 28 06 E KR oo O Kit Contents O Installation Procedures mooo f Piston ring set nar Feat gaat T Cynder gasket f wsp fo list pn rs f Cam sprocket cover base gasket Tensioner iter gaske T O The replacement of a cylinder and piston requires the removal of the engine from a motorcyle body At the time of engine installation and removal stabilize the vehicle securely with a maintenance stand or the like for safety s sake O With reference to the service manual remove the engine from the body Then remove a cylinder head a starter motor a cylinder and a piston Brush up and clean the fitting plane for a cylinder in the crank case and the fitting planes for a cylinder and cylinder head with a scraper or the like 0 Do boring processing on the cylinder Set the piston clearance at 4 100 6 100 Install piston rings to the piston On the one surfaces of the tope ring and the second ring there is an inscribed letter for each Install them as the letters face up refering to the figure below Sides do not matter for side rails 0 Be careful not to give scratches to the piston or to damage the rings O Set the EX mark at the top of th
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