/ Instruction Manual for Cylinder Set
Contents
1. Exclusively for our 48 Svage77 For exclusive use in motorcycles equipped with a CD90 engine with frame Nos from HAO3 1100005 onwards item Nos 00 00 O 000 105cc O Thank you for purchasing one of our TAKEGAWA s products O This is a piston and cylinder set exclusively for R Stage D of our own manufacture In using this set please strictly observe the following Please note that the descriptions in this manual like illustrations and photos may differ from the actual hardware Please read the following instructions before installation 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 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 This set is exclusively for R Stage D of our TAKEGAWA s manufacture Please be informed that we shall be held harmless against any claim against us whatsoever arising out of use of the products in racing and the like C The following show the envisioned possibility of injuries to human bodies or property damages as a result of disregarding the Caution following cautions 0 Since this kit is designed and developed for driving in closed races do not use the kit for running on public roads O Work2. e f q ae Second ring Loosely tighten the cam chain wet Npe gt Side rails guide roller and the cylinder side we bott Cylinder Expander 53 Pay attention to the cross section as welll the kit onto the oil return hole on i l O Apply molybdenum solution to the cylinder base of the crank case piston pin and the holes on the connecting rod small end O Attach a piston pin circlip to one of two pin holes on the piston O Loosely tighten an original hex bolt which holds the crank case on the cylinder side O Install the cylinder head with reference to the instruction manual Sleeve Interferring section Sep 08 09 Owner s Manual A WARNING Since this cylinder manual is prepared for those who have acquired basic skills and knowledge in tuning those who are technically unskilled or inexperienced are required not to do the work Specification List Displacement 01 04 7001 52 x 19 5 105 1 cm Specification List for Cylinder amp Piston Cylinder Distortion Piston Extemal diamter 4 mm from the hem ofa skirt 52 51 980 52 000 mm ro ae eer a sca 130020 13006 m 13 Extemal diameter of a piston pin 12 9947 13 000 mm Piston ring end gap size 0 157 0 38 mm 0 20 0 45 mm 0 200 0 70 mm Clearance between cylinder and piston i Clearance between piston and pin 00020 0 014 mm O Torque unit 1 kgf m
3. 06 O Some products involve detachment and installation of an engine and sepration of a crank case etc Do the installation work infallibly following Honda s genuine parts service manual O Referring to the service manual detach the engine from the frame and disassemble it O The crankcase requires processing Process the crankcase referring to the attached sheet O Measure the misalignment on the journal bearing of the crank shaft lt Shaft direction If larger than 0 10 mm replace it Bearing direction If larger than 0 05 mm replace it o Check every part 4A Caution Infallibly inspect every part and check consumable parts for damage and wear O Measure the deflection of the crank shaft lt If larger than 0 10 mm replace it What to check O Measure the internal diameter at the small end of the con rod lt If larger than 13 03 mm replace it O Measure the clearance at the big end of the con rod in the axial direction lt If larger than 0 6mm replace it 58 0 0 O0 Assemble the crankcase referring to the service manual O Measure the misalignment at two points at the big end of the con rod at right angles to the shaft as shown in the figure on the right lt If larger than 0 05mm replace it E NN E m J 1 Sep 08 09 T O Cylinder Installation Procedures Some
4. 9 80665 NJ m newton 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 QEY 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 Engine oil gt mark lt Apply engine oil where so indicated sC Owner s Manual Inspection of Cylinder Inspection of Piston O Check the inside of cylinder for wear and damage D Check the top surface of the cylinder for scratches O Clear the piston of the remaining carbon residue O Measure the internal diameters of the cylinder bore and damages Fit a piston ring into the piston and measure the at 6 positions at the piston pin angle and at the right Check the cylinder top surface for distortion with a clearance between the piston ring and ring groove angle to it X Y each at upper middle and lower parts straight edge and thickness gauge with a thickness gauge of the cylinder bore lt Service limit If the distortion is more than 0 05 mm eli Farge ian OT 7 min replace tt Treat the largest value as its internal diameter replace the cylinder lt If larger than 52 10mm at 52 replace it Calculate the clearance between a cylinder and a piston O Check the piston for damages O M
5. ce We shall be held free from any guarantee whatsoever of any trouble caused by the combined use of our products with parts not specified by us This manual should be retained for future reference Al Sep 08 N 8 O Kit Contents 01 02 7001 Piston kit No Prene 08 Rear parts Now In pacts of e e a a D7 eo E 1 3 Piston tng sel top and oi 1 orso N E Lapenn Soo i o a EN C e e o Cinder head os 1 r y C7 ferder a oorr f a E Runter pec Heck 2 fooro A o bowe pin a2 2 fooro yo EOC E 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 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 SPECIAL PARTS NESEY Co Ltd A 3 5 16 Nishikiorihigashi Tondabayashi Osaka Japan TEL 81 721 25 1357 FAX 81 721 24 5059 URL http www takegawa co jp N2 Sep 08 09 O Installation Procedures D A Caution Always be sure to tighten parts to the specified torque using a torque wrench Notice The unskilled or those without proper knowledge are requested not to do the installation work O The following show the products of our own make to which this kit cannot be installed On the use of an old type inner rotar CDI usable unusable Tap for 88 Tap for 1
6. e to y a OO Rasp the convex portions on the mating surfaces of the crankcase tillthe mating surfaces become level with each other 0 D After rasping the convex portion remove the waste cloth with care not to let the shavings go inside l the crankcase After removing the waste cloth fill the hole on the crankcase with a clean waste cloth so the parts l may not fall into the crankcase while installing the Kit X Itis likely that the shavings have fallen into the crankcase So after l you have finished installing the Kit the figure below fix piston rings and arrange the location of piston ring end gaps O Compressing the piston rings install the cylinder with care not to move the piston ring end gaps out of place Their end gaps will not be out of place O Remove the cloth used to plug holes ZA CAUTION Be careful not to damage the piston rings E Oo O Degrease the cylinder base of the crankcase and fix 8x12 dowel pins onto the dowel pin holes let your motorcycle idle for a few minutes and then replace the engine oil with the new one seman l Right side Left side n m crankcase crankcase Expander Place the cam chain guide roller on the cam chains Gasket E 5 o O Fix a cylinder gasket of the kit into 4 the cylinder base of the crankcase 4 After ectiflcation QQ Top ring
7. easure the external diameter of the piston at the specified place at the bottom edge of the piston skirt at the right angle to the piston holes lt If smaller than 51 96mm at 52 replace it C 2 Owner s Manual Inspection of Piston Ring Supplement O Measure the internal diameter of the piston pin hole O Press down a piston ring into the piston with the D If you intend to change the piston with a new one you lt If larger than 13 03mm replace it piston head and measure the clearance of the can order the one from us by the number stamped on ring end gap at the horizontal position with a the top of the piston thickness gauge Top and 2nd If larger than 0 5mm replace them Oil If larger than 0 9mm replace it DAfter removing the carbon stuck on the piston top take a note of the No stamped on the piston top O Measure the external diameter of the piston pin lt Piston pin service limit If it is below 12 98 mm replace the piston pin Example 13101 CDR T00 O Order the piston by the No stamped on the piston top gt _ gt _ _ gt ssC gt aa O Calculate the clearance between the piston and the piston pin C 3
8. only when the engine and the muffler are cool Otherwise you will burn yourself O 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 O As some products and frames have sharp pointed or protruding portions please work with greatest care Otherwise you will suffer injuries The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the following cautions O Those who are technically unskilled or inexperienced are required not to do the work Improper installation due to unskilled technique or lack of knowledge could lead to parts breakage and consequently to accidents 0 Always use new piston pin circlips gaskets and packing Wear and damage to these parts are likely to cause parts breakage and accidents O Before doing work place the motorcycle on level ground to stablize the position of your motorcycle for safety s sake Otherwise your motorcycle could overturn and injure you while you are working o 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 0 Always start the engine in a well ventilated place and do not start it in an airtight place Otherwise you will suffer from carbon mon
9. oxide poisoning 0 Before riding always check every section for slack in parts like screws If you find slack ones screw them up securely to the specified torque Or improper torque may cause parts to come off leading to accidents When you notice something abnormal with your motorcycle while riding down a road immediately stop riding and park your motorcyle in a safe place Otherwise the abnormaility could lead to accidents DAs gasoline is highly flammable never place it close to fire Make sure that nothing flammable is near the gasoline Otherwise there will be a danger of causing fires 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 O Never use any other part than the specified parts Otherwise there is a possibility of parts breakage leading to accidents 0 Always use a torque wrench to screw bolts and nuts tight and securely to the specified torque Otherwise improper torque may result in the breakage or coming off of the bolts and nuts leading to accidents 0 As the accumulation of vaporized gasoline is at the high risk of explosion work in a well ventilated place Always use high octane gasoline Otherwise troubles such as engine knocking may cause accidents Please be informed that the product specifications design and prices are subject to change without prior noti
10. precautions to take in O Attach the piston pin circlip so the Install the piston to the connecting Apply engine oil to the entire installing cylinder l ring end gap does not meet with the rod so the IN mark on the piston faces inner surface of the cylinder bore In some cases due to right and left notch on the piston pin hole and it the intake side D crankcases being out of alignment should be either on the top or at the j ii and for other reasons in installing bottom of the piston as illustrated in the cyliner the sleeve hole on the the fig 1 below crankcase s mating surface circled l portions the shaded area of the cylinder sleeve and inside of the case may interfere with one another Since such interference will lead to sleeve deformation and cause engine troubles do not fail to check the existence of interference and prevent the interference bolts gt gt f O Plug the seve hole and the cam chain hole on the crankcase with a End gaps Tips on h wtolprevent on howAloiprevent O eepiow the piston rings and the clean cloth and fix a piston pin interference l piston pin and check for jamming of circlip O O Cover the crankcase securely any foreign material by these parts with a waste cloth so the O Apply engine oil to grooves for shavings will not fall down into it piston rings and with referenc
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