Instruction Manual for / Cylinder Kit
Contents
1. N TAKEGAWA Instruction Manual for ralan SUPERHEAD 4VALVE Cylinder Kit For exclusive use with TAKEGAWA Super Head 4VALVE Item No 00 00 0000 125cc OU 0000 0O O 138 cc O Thank you for purchasing one of TAKEGAWA products O This is a piston and a cylinder set for exclusive use with TAKEGAWA Super Head 4VALVE Please strictly follow the instructions to install and use the kit As this aluminum casting cylinder can be used with our stick thermosensor you can measure temperature of the cylinder with our optional meter The sleeve of this cylinder is one piece aluminum construction with the cylinder and is ceramic chrome plated It allows this aluminum sleeve to increase more durability and more wear resistant than cast iron sleeve and to decrease the piston clearance and friction loss The piston is a lightweight design and molybdenum coating is applied on the piston skirt in order to better break in Please note Illustrations and photos may vary from the actual hardware Please read the following before installation Points to notice about sounds After installing this product in some cases a cooling fin in the cylinder may resonate making a noise In this case as a measure fix a damper included in the kit to the cooling fin of the cylinder 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 in2. consumables with utmost care Measure the deflection of the crank shaft lt If larger than 0 08 mm replace it Inspection of Crank Shaft O Measure the internal diameter at the small end of the con rod lt If larger than 13 05 mm replace it Measure the clearance at the big end of the con rod in the axial direction If larger than 0 4mm replace it C 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 07mm replace it O Measure the misalignment on the journal bearing of the crank shaft Shaft direction If larger than 0 10 mm replace it Bearing direction If larger than 0 05 mm replace it f O Installation of this kit requires in some cases engine removal and crankcase disassembly Please prepare and refer to a genuine service manual to do O A crankcase may interfere with a cylinder sleeve depending on individual differences of the crankcases If there is interference the crankcase needs O Referring to the service manual disassemble the crankcases and scrape the interfering part with a file or a hand grinder but bit by bit not to over scrape In scraping be careful not to let the cutting chips and shavings into bearings and other parts After the processing of the crankcases clean them N A J un 17 10 I O Securely fix cylinder
3. the manual We shall be held free from any kind of warranty whatsoever of products other than this product if any defect takes place on the other products than this one after the installation and use of this product If you make modifications to the products we shall be held free from any guarantee of the products This kit is for exclusive use with TAKEGAWA Super Head 4VALVE A cylinder included in this kit may interfere with crankcases depending on individual differences of the stock crankcases If there is interference the crankcase needs some modifications When you modify the stock crankcase you need removal or disassembly of engine and crankcase Be sure to see KAWASAKI s genuine service manual and work properly When installing you need new gaskets Please purchase them separately 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 The following show the envisioned possibility of injuries to human bodies or property damage as a result of disregarding the following AN Caution cautions O This product is designed for exclusive use with off highway or closed road NEVER use on public roads Please drive safely and follow the local traffic law O Work only when the engine and the exhaust system are cool to avoid burns Prepare appropriate tools and work properly to avoid the breakage of parts or injuries AS some p
4. d 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 Service limit lf the distortion is more than 0 05 mm If larger than 0 17mm replace it Treat the largest value as its internal diameter replace the cylinder If larger than 56 10mm at 56 replace it lf larger than 59 10mm at 59 replace it Calculate the clearance between a cylinder and a piston Check the piston for damages Measure 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 If smaller than 55 92mm at 56 replace it If smaller than 58 92mm at 59 replace it Figure out the clearance between cylinder and piston Inspect that the clearance is within the standard value specified in the specification list If not change the piston with a new one Owner s Manual Inspection of Piston Ring Measure the internal diameter of the piston pin hole 7 Press down a piston ring into the piston with the If larger than 13 03mm replace it piston head and measure the clearance of the ring end gap at the horizontal position with a thickness gauge Oil If larger than 0 9mm replace it Measure the external diameter of the piston pin Piston pin service limit If it is below 12 98 mm replace the piston pin Calculate the cl
5. dampers B O Apply engine oil to grooves for piston rings and with reference to the figure below fix piston rings and arrange the location of piston ring end gaps included in the kit between the cylinder cooling fins until they hit a dead end as shown in the figure below This installation is aimed at reducing a resonant sound from a cylinder cooling fin O O O Q O O Mark O Attach a piston pin circlip to one of two pin holes on the piston JS Black Expander a oa the cylinder base of the crankcase X Installing the chain guide on l cylinder the chain guide may not O Attach the piston pin circlip so the reach at the bottom of the groove ring end gap does not meet with In that case you need a oe X98 Top ring dificati th halash the notch on the piston pin hole a E al ale a NCS and it should be either on the top Pa na T e Ngee i lae ralis or at the bottom of the piston as P ston peo properly illustrated in the fig 1 below Expander End gaps O Air blow the piston rings and the piston pin and check for jamming of any foreign material by these parts Second ring Pay attention to the cross section as welll O Apply molybdenum solution to the piston pin and the holes on the connecting rod small end O Attach the piston to the connecting rod with an arrow on th
6. e piston in the direction of the exhaust side Cylinder Installation Procedures Plug the sleeve hole and the cam Put the aluminum cylinder into the chain hole on the crankcase with a stud bolt and attach the cylinder clean cloth and fix a piston pin compressing the piston rings Circlip Be careful not to move the piston ring gaps out of position A Caution Do the work with care not to damage the piston rings 4 l i O Remove the cloth used to plug holes Thoroughly degrease the cylinder base of the crankcase and fita dowel pin into the dowel pin hole Attach the cam chain guide to the cylinder Apply engine oil to the entire inner surface of the aluminum cylinder Grind here gt i O bore O Install the cylinder head with reference to the instruction manual Second ring a B2 Jun 17 10 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 Reference Value List for Cylinder Maintenance Cylinder Distortion 0 05 mm Replace Intemal diameter 56 0001 56 0150 56 100 Replace 59 0000 59 0150 59 100 Replace Extemal diamter 7 5 mm from the hem of a skirt 55 965 55 9854 55 920 Replace 7 5
7. earance between the piston and the piston pin Top and 2nd If larger than 0 5mm replace them
8. er 1 Do 01 01 0291 a i E E TnOKFST0O 1 3 Piston ring set top 2nd oil 1 125cc 01 15 020 C 0115 023 Ca Ca Ponp a ome o r Piston pin circlip 00 01 0003 Oo 6 6 Cyinder head gasket a as 7 Cinder gasket a e 8 Cylinder damper B 00 01 0031 x Please order repair parts with the Repair Part Item No Without the repair part item No we may not be able to accept your orders Some parts are only available as a set In this case please order them with the set number SPECIAL PARTS UNAEZXAMA Co Ltd 3 5 16 Nishikiorihigashi Tondabayashi Osaka Japan Va TEL 81 721 25 1357 FAX 81 721 24 5059 URL http www takegawa co jp N A J un 17 10 f Installation Procedures 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 the proper installation work According to the service manual demount the engine from the frame and disassemble it processing O Setting the cylinder in place with a dowel pin attach it to the crankcase and check for the interference with the crankcases In case there is interference see where the cylinder interferes with the crankcases the portion After disassembling the crankcases check every component referring to the service manual Caution Do inspection of every component and replacement of
9. hly flammable never place it close to fire Make sure that nothing flammable is near the gasoline It may cause a fire 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 accidents O Never use parts other than those specified by us Or the unspecified parts may break leading to accidents O Tighten parts securely using a torque wrench to the specified torque Otherwise bolts and nuts may break or come off causing accidents O Since vaporized accumulation of gasoline is quite dangerous work in a well ventilated place It is at the high risk of explosion Be sure to always use premium unleaded petrol Otherwise troubles such as knocking of an engine may cause accidents The product specifications design and prices are subject to change without prior notice We do not accept any complaint filed with us against any technical trouble caused by the combined use of our products with other manufacturers products unspecified by us NG Please retain this Instruction Manual for future reference wy A1 J un 17 10 f Kit Contents L SUUUUUUUUUUUUUUUUUN Gasket set Piston kit 01 13 0102 125cc 01 02 0142 125cc 01 13 0203 138cc 01 02 0143 138cc No Part Name Qy Repair Parts Tem No 1 Aluminum cylind
10. mm from the hem of a skirt 58 965 58 985 58 92 Replace Intemal diameter of a pin hole 13 002 13 008 mm 13 03 mm Replace Extemal diameter of a piston pin 12 994 13 000 mm 12 98 mm Replace Piston ring end gap size 0 15 0 38 mm 0 50 mm Replace 0 20 0 45 mm 0 50 mm Replace 0 200 0 70 mm 0 90 mm Replace Clearance between cylinder and piston 0 12 mm Replace Clearance between piston and pin 0 002 0 014 mm 0 05 mm Replace O Torque unit 1 kgf m 9 80665 N 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 Engine oil gt mark Apply engine oil where so indicated C Owner s Manual Inspection of Cylinder Inspection of Piston 1 Check the inside of cylinder for wear and damage Check the top surface of the cylinder for scratches Clear the piston of the remaining carbon residue Measure the internal diameters of the cylinder bore at and damages Fit a piston ring into the piston and measure the 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 an
11. roducts and frames have sharp edges or protruding portions work with your hands protected to avoid 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 because of insufficient skill and knowledge could lead to parts breakage and subsequenily to accidents Always use new piston pin circlips gaskets seals and the like Worn or damaged ones may cause accidents because of breakage of these parts Before working place the motorcycle on level ground to stabilize its position for safety to avoid the motorcycle overturning If you find damaged parts when inspecting or performing maintenance of your motorcycle do not use these parts and replace them with new ones The continued use of these damaged parts could lead to accidents 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 Before riding always check such parts as screws for loose If you find loose ones screw them securely up to the specified torque to avoid parts coming off O When you notice something abnormal with your motorcycle while riding stop riding immediately and park your motorcycle in a safe place to avoid an accident O As gasoline is hig
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