Kit Instruction Manual
Contents
1. S 12 camshaft 01 08 0012 S 15 camshaft 01 08 0015 Select a cam AUTODECOMP S 12D camshaft 01 08 0101 S 15D camshaft 01 08 0102 S 20D camshaft 01 08 0103 S 25D camshaft 01 08 0104 S 30D camshaft 01 08 0105 S 35D camshaft 01 08 0106 special parts referring to this reference data except CD90 HOUUUUO Select a cylinder HOUUUUUUUU UUUUUUUO Reference data on bore up kit For a CD90 engine 0 0 0 0000 0000000000 O0 0 L 52mmcastiron sleeve cylinder OO OUUC0U0UUU0UCTOUODEEEBUEUUOUMUUUUUUU OUD OUUU eed uuu OOOUOCOOCOUOOUOCOULNLULU LD U Teada O 0 0 0O00 L If you have purchased a cylinder head kit only Item No 01 03 8010 01 03 8011 01 03 8006 01 03 8007 please study to install these J rev Mr 25 11 Dec 14 10 N 00 00 0000 S 12 camshaft J 01 08 0012 OO0OUOUOOUOUOOUUUOOOOUOOUUUULU D SBE EHAA Reterence data on bore amp stroke up kit 125cc 000 0000 OO WA OO OOO UUMOOOCUOddUdOO Three point supporting crank shaft 48 9 mm stroke 3B oS ae S 15 camshaft 01 08 0015 NG S 20 camshaft 01 08 0020 PO es VO oo Jo loga S 25 camshaft __ 01 08 0025 S 30 camshaft 01 08 0030 S 35 camshaft 01 08 0035 OO OUUC0U0UUUU TUODEEODUEUOUMUUDUUUU OU OUD OUUU eed adda OOU U0 U 0 U0 ON OoO 00 0000 UOMUUUUUUO 48 9mmstroke U7 OU U2. OCI C2 Kit Instruction Manual gt Item No 0 00 00 000 L Applicable models and frame No excluding the case of combo kit installation Monkey Gorilla Z50J 2000001 XR50R AE03 1000001 AB27 1000001 1899999 CRF50F AE03 1400001 Monkey BAJA Z50J 1700001 XR70R DE02 1000001 Monkey R AB22 1000017 CRF70F DE02 1700001 Monkey RT AB22 1007601 CD90 HA03 1100005 Xx This product is applicable to CD90 engines with the above mentioned frame No O Thank you for purchasing one of our 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 Features O This cylinder head originally designed by us is characterized by its unique appearance completely different from the previous C type engine The new head has an enlarged top diameter and a reduced stem diameter of both the intake and exhaust valves with a new valve angle of nip and port shape We have incorporated roller bearings into the slipper of a valve rocker arm The increased weight caused by incorporation of bearings is offset by adoption of an aluminum forged rocker arm which consequently brings about higher power output at a high rotary area as a result of the synergy effect With a conventional C type engine head it i
3. e loom fa a foo a 2 Copper seating wehr 1 fooro fa C2 feinwe S ooa a a homem a SN Ca Cap screw o So oo a sari Special So Cfo OOO aes o oa Rex wrench 3mm S Sid e ro Rex wrench Fm SP id 3 toot Rex wench Sm S PP Od e COI SC dSC Mee E SPO 2 _ f_1_ Rachal bal beara og on oc CD Nahe stem sel o ono Sa Wate spring oue e aoo 2 m Oversized vae guide 00 j ooro dit Item No marked with an is not used when an automatic decompression camshaft is to be installed Dec 15 10 O Cylinder Head Installation Procedures Removethe rocker arm shaft and O Fix 8x14 dowel pins of the kit into Set the piston at the top dead adjusting bolts and nuts on the the dowel Pm holes on the cylinder center position and install the original cylinder head mE O Tighten the side bolt on the cylinder side and the cap screws on the cylinder head side to the specified torque CAUTION Be sure to tighten to the specified torque T 12N m 1 2kgf m cylinder head O Thoroughly degrease the upper surface of the cylinder O For V H S SCUT cylinder use 0 25mm head gasket O Fix the cam chain so it will not fall into the crankcase O If you find the removed TT Doli i ew amp or adjust nut damaged replace SS ln it them with a new one s i O Apply engine oil to the remove adjusting bolts and fixthese bolt to rocker a
4. Outer If the length is below 33 replace them Inner If the length is below 28 5 replace them 2E Inspection of Camshaft below 33 below 28 5 Checkthe camshaft for scratches cracks and damages INSPECTION SERVICE LIMITS Inspection of the Camshaft Bearing Slide the slide shaft and check if the decompression Inspection of the bearing Rotate the outer race of the bearings with fingers pin moves up and down on the EX side cam O Take out the C shaped ring from the cylinder head and lf the outer race does not rotate smoothly or if it is If the pin does not move up and down when you slide remove the ball bearing rickety replace either the ball bearing or cam shaft the shaft or the shaft does not slide because it has become stuck then change the cam shaft Rotate the bearing race with fingers If it does not rotate smoothly or if it is rickety replace the bearing in the case of automatic decompression camshaft Pull the slide shaft of the camshaft center And compress the spring in the shaft and release the shaft Then check if the slide shaft slides smoothly and slides back to its original position If the slide shaft does not slide smoothly or the tension is not on the spring of the slide shaft change the camshaft Inspection of Cylinder Head Check the spark plug hole and valve hole for the cracks in the vicinity Check the cylinder head for distortion with a
5. A Valve spring a Fe ee Valve cotter N Da Gyer negda O O0 U0UUUUUUUUUU0OOUUU D Reference data on bore up kit 88cc 106cc S 12 camshaft 01 08 0012 S 15 camshaft 01 08 0015 S 20 camshaft 01 08 0020 00 00 0000 S 25 camshaft _ 01 08 0025 iiun 01 08 0030 S 35 camshaft 01 08 0035 00 000 L 00 000 L OOOO ORSA O O C Select a V or H cylinder CHG 0 18 HUUUU Select a cam HUUUU S 35D camshaft 01 08 0106 OO OUUCU0UUUU CTOUODTEEEBUEUOUMUUUUUU OU OUD UUU eeu uuu OOUOCOOCOOOUOOUOUO0ULOU LU meacakassi O 0O 0O 0000 L If you have purchased a cylinder head kit only Item No 01 03 8010 01 03 8011 01 03 8006 01 03 8007 please study to install these special parts referring to this reference data except CD90 J rev Mr 25 11 Dec 14 10 N OOCL MCHA 00 00 0000 S 12 camshaft J 01 08 0012 00 00 0o000 S 15 camshaft 01 08 0015 00 10 000 S 20 camshaft _ 01 08 0020 S 25 camshaft 01 08 0025 XQ 00 00 0000 S 30 camshaft _ 01 08 0030 S 35 camshaft 01 08 0035 OOUUUUUUU 39mmstroke S 25D camshaft 01 08 0104 S 30D camshaft 01 08 0105 S 35D camshaft 01 08 0106 HOUUUHUUUUUUUUUUUUEEUURPEUUUWUUUUUod If you have purchased a cylinder head kit only Item No 01 03 8010 01 03 8011
6. Free length of valve spring outer 33mm Replace inner 28 5mm Replace O Special tool Valve spring compressor set of Item No 00 01 1005 O Torque unit 1 kgf m 9 80665 Ni m hewton meter O This mark shows molybdenum solution This solution is a mixture of molybdenum grease and engine oil in the ratio of 1 1 Apply molybdenum solution or assembly paste to the portions where it is indicated that molybdenum solution needs to be applied NEW O This mark shows those parts to be replaced with every overhaul Do not fail to replace these parts every time they are overhauled O This mark means Alumi Special heat resistant lubricating agent Alumi Special heat resistant lubricating paste and grease which prevent galling from high temperatures and heavy loading and adhesion Purpose good for those parts which get hot like a spark plug and exhaust manifold yx Never apply this to any parts other than the specified parts C INSPECTION SERVICE LIMITS Splitting of Valve Check each valve for bending baking and Inspection of Valve Seat Compress the valve spring using a valve spring damages Remove carbon sediment in the cylinder head compressor Measure the exterior diameter of the valve stem at combustion chamber and valve the sliding surface of the guide with a micrometer Dissolve red lead primer with oil or the like and apply CAUTION Never compress it more than necessary a Service Limit IN
7. So the paricuiariy one t6 Exed IE Upper IMIP OT TEV UNONG OVET TEVOIMIONS will result in nonsmooth revolutions of the engine not only adversely use of a stock sprocket will result in severe wears of parts because of too ffectina th nele balan breakingih nemih low gear not only adversely affecting the engine life but also breaking the SUS OH GE ME OMISE OUAS DEARI tre ONNE I ME Wor t CASE engine in the worst case Therefore please change the sprockets with Titanium valve spring retainer optional the high geared one gt This S gt HonAl RI iai s is Super Head has optional titanium valve spring retainers This kit cannot function on its own Referring to the Titanium retainers are about 30 lighter than steel retainers attached sheet please purchase a kit for exclusive Tre surface is treated with a special coating of which hardness is HV1000 use with this kit This does not apply if you have above for added shock resistance and wear resistance purchaed a full kit Item No 01 12 084 2 pes Others gt Oil cooler i v The installaiton of this kit increases the heat release value of the engine DA wey 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 Carburetor manifold The surface of a manifold compatible with R
8. 4 47 mm it to the valve face evenly Special tool Valve spring compressor set of EX 4 45 mm item No 00 01 1005 Replace the bent baked or damaged valves with new ones O Strike the valve once and lightly with a valve punner and rotate it Removal of Valve Cotter l Wipe off the red lead primer on the valve faces and Use a magnet to remove the cotter if it does not come Inspection of the Valve Guide strike the valves once and lightly with the valve punner Valve spring compressor off easily Measure the inner diameter of the valve guide without rotating them and check the contact surfaces Remove first the valve spring compressor and then Service Limit IN 4 56 mm for damages or scratches the following parts EX 4 57 mm Valve spring retainer Replace the valve guide or cylinder head if the valve Valve spring Inner amp Outer guide is scratched or damaged Valve Inner spring Outer spring Valve spring retainer Valve cotter 3 Outer diameter of the valve stem subtracted from the N CAUTION If the valve is damaged at its end do not inner diameter of valve guide is a guide clearance remove it forcibly but rectify the end first Service Limit IN 0 09 mm before removing it EX 0 12 mm INSPECTION SERVICE LIMITS Inspection of Rocker Arm Check the rocker arms for scratches damages and Jamming And check if the bearing rotates smoothly Measure the internal diam
9. Stage amp old Super Head with a port diameter of 24 25 on the side of an inlet pipe will not be level with the cylinder head because of the difference in manifold diameter Enlarging the manifold s port diameter on the manifold side will bring about smoother output characteristics 25 26 A serial number is punched on the cylinder head just for the sake of administration You may be requested to informus of the number when ordering repair parts In case you are not able to order parts because you do not have the repair parts numbers or for other reasons please place an order in the following way x Make a note of the number punched on the left side of the cylinder head Example of how to order gt Super head kit repair head No 2SM 00001 gt Intake valve Qty 1 piece si 2SM 00001 A We advise you to use a special carburetor kit for Super Head R A head No 2SM 00 is stamped here For the part numbers of the carburetor kits please refer to the parts list of g our recommendations on page 3 ener O Special manifold only for Super Head R r a VM26 003 02 2541 mes PE28 003 02 2551 N About camshaft Ie If you have purchased a cylinder head kit a special camshaft is needed separately Camshafts with a few kinds of profiles are available from us to w meet different uses and engine displacement Even if you have purchased a full kit yo
10. an accident 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 torque may cause parts to come off O 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 Always use high octane gasoline Otherwise troubles such as engine knocking may cause accidents 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 Cautions before riding Revolution About fuel a a _ Upper limt of revolutions varies depending on the installed cam shafts etc Whenever regular gasoline is remaining in the fuel tank always replace it Referring to the camshaft comparison graph on page A install a mals high octane gasoline revolution counter to make sure that you drive the engine at revolutions With this kit installation a centrifugal filter will be lost So please install a below the upper limit GIy S Clutch WIM nal Ol Miter Oia cuten Take note that idling and sudden acceleration in the 1st and the 2nd gears About change of a sprocket l ae The installation of this kit will increase the power of your vehicle
11. clearance with an adjust screw IN 0 05 0 08 when cold OUT 0 05 0 08 when cold Dec 15 10 Ve applying engine oil a little to O Install socket set screws of the kit an O ring on the inspection cap of to two taps on the cylinder head the kit attach the O ring to the ports which will not be used for inspection cap and fix the manifold installation and tighten inspection cap with 5x15 cap them to the specified torque screw of the kit and tighten up the screw to the specified torque A CAUTION Be sure to tighten to the specified torque T 5N m 0 5kgf m These taps will not be used O Apply engine oil a little to insection cap O rings of the kit and fix them to the breather cap and the inspection cap Then fix and tighten the breather cap on the intake side and the inspection cap on the exhaust side with 5x15 cap In case a breather cap is used D e screws of AHE the specified O Following the instruction manual for torque the relative carburetor install the CAUTION Be sure to tighten to carburetor the specified torque T 6N m 0 6kgf m O Install the drive sprocket CAUTION Be sure to tighten to the specified torque T 12N m 1 2kgf m CAUTION Be sure to tighten to the specified torque T 70 11N m 0 70 1 1kgf m O Pour engine oil from the side bolt hole in the
12. what we can safely say is that the ignition system of this kit is compatible 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 As the stock clutch cannot be used a centrifugal filter gets unavailable Therefore install an oil filter outside Please install an oil cooler when necessary Engine oil must be API SF or higher class such as SAE 10W 40 15W 50 which are our recommendations Change the sprocket with the one which meets the output and specifications This kit cannot be used alone if you have purchased a cylinder head kit If you have not purchased our special engine parts please purchase special parts with reference to the attached Reference data on kit This kit is compatible with only those engine parts recommended by us So please replace the engine parts not recommended by us with those of our recommendations Since this kit is designed and developed for driving in closed races do not use the kit for running on public roads In case you have purchased this product as a combo kit the above mentioned applicable models vary depending on the type of drive sprocket When the 124cc Kit is to be used together with a standard crankcase the crankcase needs to be processed in the section where a sleeve is to be attached As we accept the proc
13. with the shaft of the camshaft being pulled toward you so that the decompression function can be deactivated Attach a snap ring in the shaft groove CAUTION Do not expant the snap ring more than necessary WARNING Always use a new snap ring at any time and do not reuse it O Tighten the adjusting nut to the specified torque CAUTION Be sure to tighten to the specified torque T 10N m 1 0kgf m P O Apply engine oil a little to two kinds of O rings for the right side cover and fix them to the right side cover Then tighten them with 5x12 cap screws of the kit to the specified torque CAUTION Be sure to tighten to the specified torque T 6N m 0 6kgf m A OApply engine oil a little to a left side cover O ring of the kit and fix it to the left side cover Then fix them to the cylinder head with two 5x15 cap screws and with a 5x10 cap screw of the kit and tighten O Check that the T mark on the flywheel is aligning with an alignment mark on the crankcase them to the specified torque Be careful of the location of screws CAUTION Screws must be used at the specified positions only CAUTION Be sure to tighten to the specified torque T 6N m 0 6kgf m O Adjust the valve
14. 01 03 8006 01 03 8007 please study to install these special parts referring to this reference data except CD90 HUHUUUUUUUUUUUUUUUO Reference data on bore amp stroke kit 100cc 00 00 0 0U 00 000 L OO OUUCU0UUUU TOUODEEODUEUOUMUUUDUUUU OU OUD eau uuu N P rev Mr 25 11 Dec 14 10 N Reference data on bore amp stroke up kit 106cc sa OOHOHOUOUOUOUOUEUTUUUUUUUUROOO Three point supporting crank shaft 50mm stroke 3B 00 00 0000 S 12 camshaft 01 08 00 00 0000 S 15 camshaft 01 08 0015 do lo doga S 20 camshaft _ 01 08 0020 0 00 0000 S 25 camshaft _ 01 08 0025 S 35 camshaft 01 08 0035 HO OO0O0000 1g0000000000 Castiron sleeve cylinder LOD Ly HOUUUUDUUUUOE 50mm stroke 2B 0 0 0 0 HUOQHUODUUUODUOU Select a 2B or 3B crank UL EOE oo Select a V or H cylinder OU ae U DOOOOUOOOUO0D Castiron sleeve cylinder OO O0U0 00 0 dae UOUUUUOU Plated cylinder U U UUUU OO00000000 go Reauirecrankcase modification S 20D camshaft 01 08 0103 S 25D camshaft 01 08 0104 S 30D camshaft S 35D camshaft 01 08 0106 x0 0 0 0 0 00 0o00 er UU UU addoU OOOCOOOOOOOUOOUOOOOOOOOUMUUUOUOUUUU If you have purchased a cylinder head kit only Item No 01 03 8010 01 03 8011 01 03 8006 01 03 8007 please study to install thes
15. U UU U OS Select a 2B or 3B crank 00N S 25D camshaft 01 08 0104 S 30D camshaft 01 08 0105 00 0000 S 35D camshaft 01 08 0106 OOOCOOOOOOOUOOUOOOOOOOOOUMUUUOUOUUUU If you have purchased a cylinder head kit only Item No 01 03 8010 01 03 8011 01 03 8006 01 03 8007 please study to install these special parts referring to this reference data except CD90 J Sep 06 11 N 00 00 0000 5 12 camshaft J 01 08 0012 Serres gz COO00000000000000000 0 D Reference data on bore amp stroke up kit 138cc 000 0000 OO WACO OOOOU OUUUUUUOUUOOOD Three point supporting crank shaft 54mm stroke 3B 00 00 0000 S 15 camshaft 01 08 0015 Da S 20 camshaft 01 08 0020 ES L oo Jo loga S 25 camshaft __ 01 08 0025 S 30 camshaft _ camshaft 01 08 0030 S 35 camshaft 01 08 0035 OO OUUC0U0UU0UU0UCTOUODEEEBUOUOUMUUUUUU OU OUD UUUU ead dedi OOU U0 U00 eee I ey 0UU LU OOUUUUUUEU 54mmstroke UMBVUUUUUUU Be Select a 2B or 3B crank 0 0 0 0D S 20D camshaft 01 08 0103 S 25D camshaft 01 08 0104 S 30D camshaft 01 08 0105 00 0000 S 35D camshaft 01 08 0106 OOOCOOOOOOOUOOUOOOOOOOOUMUUOUOUUUU If you have purchased a cylinder head kit only Item No 01 03 8010 01 03 8011 01 03 8006 01 03 8007 please study to install these special parts referring to this re
16. ally unskilled or inexperienced are required not to do the work After the disassembly of the hardware and a cylinder head clean them before the inspection and measuring And then blow them with compressed air and dry them well Engine oil for lubricating the camshaft will be supplied through the oil passage in the cylinder head Clean the oil passage before assembling the cylinder head After the disassembly of hardware put a mark on the hardware so they can be reinstalled correctly to their original position Reference Value List for Cylinder Head Malitehance Standard Valve clearance intake 0 050 0 08mm when cold exhaust 0 05 0 08 mm when cold Cylinder head distortion 0 05mm Modify or replace Inside diameter of valve rocker arm 10 05mm Replace Outside diameter of rocker arm shaft intake exhaust 9 92mm Replace Clearance between a rocker arm and a shaft 0 0130 0 037mm 0 10mm Replace Inside diameter of valve guide intake 4 56mm Replace the guide or the head exhaust 4 57mm Replace the guide or the head Outside diameter of valve stem intake 4 471mm Replace exhaust 4 45mm Replace Clearance between a valve stem and a guide intake 0 01 0 037mm 0 09mm Replace the guide or the head exhaust 0 025 0 052mm 0 12mm Replace the guide or the head Valve seat contact width Intake 0 8 1 0mm 1 5mm Modify or replace the head exhaust 1 00 1 2mm 1 7mm Modify or replace the head
17. ase use 1 0mm 3 pcs metal head gasket with green O ring and Tighten nuts on the stud bolt black rubber gasket diagonally to the specified torque in a few steps CAUTION Be sure to tighten to the specified torque T 12N m 1 2kgf m The above applies only to the old type cylinder kits Included part for intake side Dowel pin 8 x 12 NOTE The supplied dowel pin will not be used in case a dowel pin is pressed into your camshaft Jj B Ls Dec 15 10 rev Feb 21 11 Please use appropriate gasket O Fix a cam shaft circlip of the kit In case you install an and fix the cam shaft automatic decompression At this stage set the location of cam shaft ring end gap of the circlip not to Set a cam sprocket washer through meet the notch on the cylinder head a weight and set two black 5x12 cam hole cap screws into upper and lower holes O Attach the camchain to the cam sprocket And place the weight to face the O mark and install it with two black 5x12 cap screws At this time apply a thin coat of Alumi Special the heat resistant lubricating agent to the thread of the cap screw Then align the T mark on the flywheel with the alignment mark on the crankcas
18. cam chain tensioner and tighten the side bolt CAUTION Be sure to tighten to the specified torque T 8N m 0 8kgf m O Add engine oil in amount specified by the clutch kit you use O With reference to the service manual attach the drive chain O With reference to the service manual mount the engine on the frame A CAUTION Be sure to follow the instructions in the manual sx Inthe case of a three point support crank shaft 3B kit fix a generator cover according to crank kit installation instructions In case you use a breather cap fix a breather hose according to oil catch tank installation instructions In case you use a breather cap fix a breather hose according to oil catch tank installation instructions pe B Item No for a blade hose set 1 m with clips 000 03 054 x Engine Starting O Check that the ignition key and the fuel cock are turned OFF Continue kicking the starter for a while to circulate the engine oil all around the engine O Install the spark plug Apply Alumi Special a little to the threaded part of the plug and fix it A CAUTION Be sure to tighten to the specified torque Designated plug ooo ooo Ch 0o Thermal value DENSOG oo o Therma
19. e Ser neay gz CO00000000000000000 0 N special parts referring to this reference data except CD90 Da J rev Mr 25 11 Dec 14 10 f N Swe pegy L0000000000000000000 L0 Reference data on bore amp stroke up kit 124cc goo 000 E ren 00 00 0000 Saagi O oo o0000 000000000 S 12 camshaft 10108 0012 Three point supporting crank shaft 54mm stroke S 15 camshaft 01 08 0015 00 00 0000 S 20 camshaft 01 08 0020 oo lo ago0g0 S 30 camshaft 01 08 0030 Se ee ee S 35 camshaft 01 08 0035 a oo oo o000 oo o 108900 6 pa an O00000 Selecta cam E CI Ww 000000000 54mmstroke 5 00 00 00000 000000000 0 fCastiron sleeve cylinder AUTODECOMP S 12D camshaft 01 08 0101 S 15D camshaft 01 08 0102 S 20D camshaft 01 08 0103 S 25D camshaft 01 08 0104 S 30D camshaft 01 08 0105 0o0 00 0000 S 35D camshaft 01 08 0106 x0 0 0 0 00 O0 U00 U a OO UU OU UU OUOUO UU UU UU UU UUUUUUMoUUUUoUoUUU HOOUUUDUUUDUUUUDUUUEUUUEUUWOUUOUUOUU If you have purchased a cylinder head kit only Item No 01 03 8010 01 03 8011 01 03 8006 01 03 8007 please study to install these special parts referring to this reference data except CD90 Y P rev Mr 25 11 Dec 14 10 N Da SSC MCA 00 000 L Do oo OO O0U U0U00 00 000 L0
20. e aligning the Notch O Check that the circlip is right in the circlip groove Warning Do the checking without fail 7 3 O mark on the cam sprocket with the alignment mark on the cylinder head chain tensioner O Holding the crank tighten the cap screws which are attached to fix a WES ae Attach the cam chain to the cam sprocket and fix them with a cam sprocket plate and two 5x12 black cap screws included in the kit At this point apply Alumi Special a little to the threaded parts of the cap screws Then align the T mark on the flywheel with the alignment mark on the crankcase and align an O mark on the cam sprocket with the alignment mark on the cylinder head the cam sprocket to the specified torque CAUTION Be sure to tighten to the specified torque T 10N m 1 0kgf m aa z O Check that the T mark on the flywheel is still aligned with the O mark on the cam sprocket O Pass a 6mm snap ring and a plate into a thumb screw supplied in the Camshaft Kit attach it to the shaft tip of the camshaft comp and pull the shaft toward you B 2 When installing an automatic decompression cam shaft Adjust the valve clearance on the EX side
21. els and work with enough care following instructions in the service manual Besides this instruction manual as well as HONDA s service manual is prepared for those 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 You are kindly requested not to contact us about the combination of our products with other manufacturers A serial number is engraved on the cylinder head You may be requested to inform us of the number when ordering parts Bolts and nats will be reused However be sure to replace worn down or severely damaged ones with new ones Never use liquid packing It may plug the oil passage and in the worst case break the engine 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 Determine the heat value of a spark plug depending on how much it is burnt In vehicles originally with a resistor plug use a resistor plug Never use this kit on the point ignition system motorcycle Please be informed that
22. essing send the crankcase to us after carefully reading the instruction manual for your Cylinder Kit Or contact your local specialist shop handling internal combustion products We not recommend using stock crankcase with this kit Because of stock crankcase will not hold the power of this kit Use Special crankcase Kit 100 106cc 01 00 0038 124cc 01 00 0039 138cc 01 00 0040 Important notice 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 Cauti The following show the envisioned possibility of injuries to human bodies or property damages as a result of disregarding the following 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 O Work only when the engine and muffler are cool at below 35 degrees Celsius Otherwise you will burn yourself Prepare right tools for the work Otherwise improper work could cause breakage of parts or injuries to yourself As some products and frames have sharp edges or protruding portions please work with utmost care Otherwise you will suffer injuries Always use new gasket and packing The worn or damaged parts may cause the engine troubles s A 1 Dec 15 10 rev Mar 25 11 rev Apr 13 11 The following show the envisioned p
23. eter of the rocker arms Unfasten an adjust bolt and check it for scratches If it is scratched change it with a new one LA Scratchon Uneven seat width k lt r 7 Br a r Service limit If the inner diameter is bigger than 10 05 mm replace the rocker arm the seat J A Contacting at a low position Contacting at aig iach Inspection of Rocker Arm Shaft 7 Check the rocker arm shaft for bending scratches and damages Measure the external diameter of the rocker arm shaft Service limit lf the external diameter is smaller than 9 92 mm replace it Service Limit Need to be fixed when the service limit at IN is more than 1 5 mm and when the service limit at EX is more than 1 7 mm lf there is a scratch on the valve seat modify the seat If the contact width is wide narrow in a high or low position modify the seat Ask machine shop for modification Outer diameter of the rocker arm shaft subtracted from the inner diameter of rocker arm is a clearance Service limit If the clearance is bigger than 0 1 mm replace the rocker arm shaft Inspection of Valve Spring Retainer Inspect the contact surface of valve spring and retainer or keepers If they are in good condition they may be reused Replace as necessary Inspection of Valve Spring Check the valve springs for scratches and damages Measure the free length of the valve springs
24. ference data except CD90 J rev Sep 06 11 Dec 14 10
25. g purpose Also the engine output will vary significantly depending on the using exhaust system length of inlet pipe carburetor diameter compression ratio ignition system ignition timing fuel or natural phenomenons such as ambient temperature or atmospheric pressure Camshaft comparison data list Note As these are the data measured on a Dyno Jet the data differ from the actual driving Please refer to them just for a reference The engine power varies significantly depending on the temperatures N 88 cc Test Vehicle MONKEY 52X41 4 88cc Carburetor MIKUNI VM26 Exhaust Racing Muffler 14 n g LOTEEN 12 aan v N 7 N lt A p S Ww L Pad L j 7 20 cam 19 I2cam Vv 7 30 cam 4 iawn A 1 L 6 m sA a dee 4 Ao 7 fos I A VA 0 RPM x 1000 3 4 5 6 7 8 10 11 12 13 14 15 can ee 20cam 30cam Test Vehicle MONKEY 52X41 4 88cc Carkuretor MIKUNI VM26 Exhaust Racing Muffler 14 n z 7 TSK g Fa 2 cam 12 F N S W lt x 7 L v e fa rae cam i 10 Fi ra rd 15 cam Y IAT 2 AG s 7 f A F TL 7 4 mer A of T a 7 r ON 7 I 2 7 oy 0 l RPM x 1000 3 4 5 6 7 8 10 11 12 13 14 15 25 cam 35 cam 124 cc Test Vehicle MONKEY 54X54 124cc Carburetor KEIHIN PE28 Exhaust Racing Muff
26. l value Attach the plug cap to the spark plug O oO Wipe off the dirt and dust on the engine Turn ON the fuel cock and ignition key and start the engine A WARNING Work only ina well ventilated place When installing an N automatic decompression cam shaft Xx When starting the engine keep the stroke of the kickstarter arm wide enough Usually the stroke amount of the kickstarter arm becomes short especially when a dry type clutch is installed onto the engine which makes it hard to start the engine Adjust the angle at which to install the kickstarter arm and start the engine taking sufficient stroke amount Take the sufficient stroke amount Check for any abnormality such as an abnormal sound If nothing abnormal is detected carry out a shakedown for about 30 to 50 km and check the valve clearance again A CAUTION Work only when the engine and the muffler are cool Carry out a shakedown again for about 100 to 150 km O After the shakedown double check for any abnormality such as an abnormal sound and blow by gas If any abnormality is detected disassemble the engine again and check each section A WARNING Never re use parts which cannot be re used Dec 15 10 INSPECTION SERVICE LIMITS A WARNING Since this cylinder head manual is prepared for those who have acquired basic skills and knowledge in tuning those who are technic
27. ler 2 19 o 18 0 17 A 16 Hu 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 2 3 4 5 6 7 9 10 11 12 13 30 cam 12 cam Test Vehicle MONKEY 54X54 124cc Carburetor KEIHIN PE28 Exhaust Racing Muffler 14 20 gt ag 9 35 cam ioe Da a 18 g gt oars 17 fo peagi 25 cal s 7 16 mti 7 lt 15 0 14 13 12 11 10 9 8 7 6 5 4 3 2 1 RPM x 1000 0 2 3 4 5 6 7 9 10 11 12 13 _ ee ul Q 3 15 cam 14 J Dec 15 10 f Please note that in ordering repair parts be sure to quote the Repair Part Item No Otherwise we may not be able to accept your orders HO OU U0U00 N Kit Contents io 00 S OU There are some parts however for which we are not in a position to accept your order in just the quantity to be used In this case please take them in the quantity packed 00 000 LL00 00 000 0oo0o 00o 00o0ogo EU0U U0 OO0000 00 00 op000 00 00 1000 f Parts Name Parts Name No a Gam sprocket SSCSCSC C OO 6 Cap scewsa OOO efre TT pe o e E Sid e id oe Cap screw 5x15 Cap screw 5x10 Cap screw 5x12 SUS SUS SUS
28. onkey Gorilla Oil catch retum tank kit 07 05 0010 O Only in case a head breather cap is used Oil catch tank kit 09 04 032 x It s impossible to install this product to a CD90 motorcyle because there is no compatible carburetor Please take note that this product is applicable to engines with the above mentioned CD90 frame No only About optional camshafts O The following camshafts compatible with this Kit are available from us Referring to the below mentioned output graphics please select a camshaft to match your usage and engine displacement for your great riding pleasure S 12D camshaft 01 08 0101 option S 1D5 camshaft 01 08 0102 Packed together with Monkey Gorilla 88 106 Packed together with CD90 S 20D camshaft 01 08 0103 Packed together with Monkey Gorilla Bore Stroke Up 124 S 25D camshaft 01 08 0104 Packed together with Monkey Gorilla Bore Stroke Up 138 5 300_carshatt 01 08 0105 S350 camshaft 01060106 O About Camshafts Number The bigger the numbers of XX YY are the wider the durations are With these cam shafts the output power will produce more to high rpm range While the smaller the numbers are the narrower the durations are With these camshafts the output power will produce more to low to mid rom range We supply the suitable camshaft depending on the displacements When choosing the optional camshafts please choose the camshaft referring to the camshaft data chart to suit your ridin
29. ossibility of human death or serious injuries to human bodies as a result of disregarding the following cautions Those who are technically unskilled or inexperienced are required not to do the work Improper installation because of insufficient skill and knowledge could lead to parts breakage and subsequently to accidents Before doing work secure the motorcycle on level ground for safety s sake Otherwise your motorcycle could overturn and injure you while you are working 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 As gasoline is highly flammable never place it close to fire Make sure that nothing flammable is near the gasoline It may cause a fire 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 O Never use the parts unspecified by us This may lead to parts breakage and consequent accidents 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 accidents 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
30. rms of the kit O Tighten a cam chain guide roller of the cylinder to the specified torque CAUTION Be sure to tighten to the specified torque T 10N m 1 0kgf m O Align a T mark on the flywheel O After applying Alumi Special a little with an alignment mark on the to the threaded part of the cylinder head stud bolts fix a copper washer of the kit to the lower left part oil line and washers of the kit to other parts Then fix four cap nuts of the kit and 6x18 cap screws as indicated in the figure below and loosely tighten them n a __ dice Please use appropriate gasket Note These cylinders have a marking on the cylinder head surface or its Item No is stamped on the fin side crankcase Then set the piston at TDC Top Dead Center Fix the rocker arms to the Super Head Apply molybdenum solution to the original rocker arm shaft and fix it on the exhaust side Apply molybdenum solution to a rocker arm shaft of the kit as well and fix it with its slit part pointing to the cam chain side Copper sealing washer O Apply engine oil to a aroe on the camshaft COMP which please fit to a cylinder head And put a provided 8x12 dowel pin into the centerhole in the camshaft Cap screw O No parts number stamped on your cylinder or cylinder uses green O ring ple
31. s difficult to replace the cam shaft with the cylinder head being installed However with this Kit the cam shaft can be detached without removing the rocker arm leaving the bearings on the oil line side of the cam shaft on the cylinder head side Therefore this makes it easy to change the cam shafts even when the engine is mounted on the vehicle Moreover the new incorporation of the automatic decompression function into the camshaft makes it easy to press down on the kickstarter arm to the end reducing strain on the kickshaft and gear Please read the following carefully before starting installation Please note that in some cases the illustrations and photos may vary from the actual hardware 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 and for exclusive use in motorcycles equipped with a bore up and bore stroke exclusively for this kit as well Therefore please take note that this kit cannot be mounted on other applicable models of motorcycles or motorcycles not equipped with bore up etc exclusively for this kit Installation of this product requires removal and reinstallation of an engine and disassembly of a clutch Please prepare HONDA s genuine service manual for the above mentioned applicable mod
32. straight edge and thickness gauge Thickness gauge Service limit If the distortion is over 0 05 mm rectify or replace the cylinder head C4 INSPECTION SERVICE LIMITS Installation of Bearing To the head attach the valve spring with a narrowly Install the bearing to the cylinder head with the shield pitch side pointing to the combustion chamber facing the camshaft CAUTION Be sure to place the narrower pitched Install the C shaped ring with its round portion facing portion of the valve spring to face the the bearing combustion chamber side Y Combustion Narrower chamber Direction of the round face Direction of the shield Compress the valve spring with a valve spring compressor And apply a thin coat of grease to valve Valve Assembly cotters and install them ae AUTION D the valve spri th D Install valve spring seats and new valve stem seals A Chie 7 e valve spring more than Apply molybdenum solution to the sliding surfaces of the valve stems and fit the valves into the valve guides rotating valves slowly with care not to damage the stem seals Valve U n O Strike lightly the end of valve stems a few times so the Stem seal NEW ers AK Stem seal NEW valves and cotters fit together well Valve spring inner CAUTION Be careful not to damage the valves geo Spring seat n id Valve spring outer
33. u can study to use them as an optional extra in addition to For those who have purchased a cylinder head alone selection sets are camshafts inclued in the full kit For more information please refer to available to meet your combination demand for engine displacement etc enclosed paper Please study the required contents of the kit referring to Reference data An inspection cap and a breather cap are included in this kit In case you onkit on enclosed paper W a breather cap please use an oil catch tank at the same time Please contact your dealer for more details about the kit or enquiries p a 2 Dc 15 10 rev Mr 25 11 rev Apr 13 11 Te Engine parts of our recommendations x This kit is only compatible with those engine parts recommended by us So please replace the parts not of our recommendations with those of our recommendations Parts of our recommendations Special clutch kit Clutch Dry type clutch kit tock C D I Ignition system Hyper C D I 07 02 15 D I Magnet 05 02 0511 Mikuni VM26 carburetor kit 03 05 0484 Keihin PE28 03 05 0981 carburetor kit Mikuni VM26 cin Keihin PE28 Carburetor 03 05 098 Mikuni VM26 o Keihin PE28 carburetor kit 03 05 095 Mikuni VM26 CRF50 03 05 3245 Oil pump Super oil pump kit 01 16 0051 Cam chain High duty cam chain kit 1OScc O Only in case of a cylinder head kit 124cc 01 14 0003 C ee ros Oil catch tank Only for the M
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