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DOHC 4-VALVE CYLINDER HEAD KIT
Contents
1. o Align the alignment mark IN mark on the supplied i intake cam gear with the one on the idle gear Then align the cam top with the top hole on the cam gear See the fig below And place the supplied stopper pin right in the position shown in the figure below to insert it and install it using the supplied cam gear plate and 5x12 cap screw ANNote Never fail to align the alignment marks Cam top hole Alignment mark Stopper pin o Apply engine oil to the cylinder head and the bearing of the cam holder o Fix the crank and tighten the cap screw which holds the cam gear to the specified torque Note Be sure to tighten to the specified torque T 10 NU m 1 0 kgf m o Apply either engine oil or molybdenum disulfide solution to the slipper of the camshaft Me s B2 Aug 01 06 fo A fo Lightly apply Aluminum Special the heat o Attach the supplied 6x20 cap screw to the o Recheck the valve clearance with a thickness side of the cylinder head and tighten itup gauge resistant lubricating agent to the threaded A Note Be sure to tighten to the specified torque 4 Note Remove the dust or dirt from the thickness Portion of the 5x22 cap screw and fix the head T 12 N m 1 2 kgf m gauge if any cov
2. f N This cylinder head manual is prepared for those who have acquired basic skill and knowledge Therefore those who are technically inexperienced or unskilled are requested not to do the installation work IM Cylinder Head Manual Unit of torque 1 kgf m 9 80665 N m newtonmeter Ref erence Val ue Li st Val ve d earance X 0 15 0 O3nm Wien col di Cyl i nder Head D storti on e 0 O5nm Val ve Lifter Internal Bore D aneter 20 010 20 026nm 20 035nm External Lifter D aneter 19 978 19 993nm 19 970nm Val ve Gui de Internal D aneter 3 800 3 812nm 3 89nm Val ve Stem External DO aneter 3 775 3 790nm 3 7AM 3 765 3 780nm 3 nm d earance bet ween Stemand Gui de 0 010 0 037nm 0 04nm 0 020 0 047nm 0 OSnm Contacting Wdth of Val ve Seat 0 8 10nm 1 5nm 0 9 1 1nm 1 5nm Free Length of Val ve Spri ng 38nm 37 5nm x As for an optional cam please refer to its instruction manual O Valve Clearance Adjustment Valve clearance needs adjusting when the valve seat is cut or a valve camshaft or valve lifter are replaced Place the thickness gauge between the camshaft and valve lifter to measure the clearance O IN EX valve clearance 0 15 0 03 mm when cold For 125cc IN valve clearance 0 15 4 0 02 EX valve clearance 0 15 0 2 0 02 As for an optional camshaft please refer to its instruction manual Remove a camshaft then valve lifters and shims Use a val
3. b DOHC 4 VALVE CVLINDER HEAD KIT Item No H UU for 88cc amp 95cc H O0 O0 for 106cc 8 115cc f 0 00 for 124cc U U U M Fitting nkey Gorilla Frame Nos Z50J 2000001 L AB27 1000001 O Thank you for purchasing one of our TAKEGAWA s products Please strictly follow the following instructions in installing and using the kit You are required to understand the contents of this Instruction Manual by carefully reading it before installing the kit Please read the following before starting the installation o This cylinder head is compatible only with those engines described in Engine Specifications of Our Recommendation on p A2 and the specified motorcycles If there is any incompatible part change it with a compatible one o In case this set is to be used in a stock crankcase a portion of the crankcase to insert the sleeve needs processing or scraping because the crankcase and cylinder sleeve interfere with each other For the details or more information please contact your local motorcycle dealer Change the sprocket with the one to match the output and specifications The type of spark plug is different Change the plug with the special one And determine the heat value of a spark plug depending on how much it is burnt For the details please see the attached sheet In vehicles originally with a resistor plug make sure to use a resistor plug Always use a torque wrench to screw bolts a
4. o Compressing the valve springs with a valve spring compressor attach the valve coiters N CAUTION Do not compress the valve springs more than necessary o Strike lightly the tip of valve I stems a few times so the valves and cotters fit together well ANCAUTION Be careful not to damage the valves FC 3 Aug O1 06 f O Positions of Cam Gear and Dowel Pin p Change of the position of a cam gear dowel pin will make it possible to change the valve timing o The lobecenter at each dowel pin position is as per the illustration below However as this is just for your reference only figure out the exact angle with a timing protracter and dial gauge EX IN LOBECENTER LOBECENTER LOBECENTER100 LOBECENTER 110 LOBECENTER 105 LOBECENTER105 LOBECENTER 100 LOBECENTER 110 Positional relationship between a dowel hole and lobecenter Crank angle ATDC Positional relationship between a dowel hole and lobecenter Crank angle BTDC yx Caution o Shifting of the pin position from the originally pre set position will degrade the performance If you would change the pin position please always try to do so without changing the cam top position as per the above illustrations o Those who are not familiar with the valve timing are required not to shift t
5. o Apply engine oil to the seating face of the Atthis stage align the alignment mark on the threaded portion of the supplied cylinder head nut idle gear with the notch on the cylinder head and install the cylinder head nut when the T mark on the flywheel is aligned F __ with the alignment mark on the crankcase Note Don t misunderstand the alignment mark on the idle gear o Attach the rubber packing green black to the oil lines on the cylinder surface o Install the cylinder head tightening it to the specified torque diagonally in a few steps Note Be sure to tighten to the specified torque T 12 N m 1 2 kgfi m g 4 i s Cas l sa B1 Aug 01 06 o Attach intake and exhaust camshafts to the cylinder head Note Don t make mistakes in selecting IN and EX camshafts x IN and EX marks are on the camshaft in the embossed lettering o With a supplied set screw hold the idle gear shaft and tighten it to the speficied torque NGaution Always be sure to tighten to the specified torque T 8 N m 0 8 kgfid m O Just like the intake cam gear place the exhaust cam gear EX marked in the position shown in the figure below to install it Note Be sure to align the alignment marks Cam top hole Stopper pin
6. 013 14961 KT7 013 14962 KI7 013 14963 KT7 013 14964 KT7 013 14965 KI7 013 14966 KT7 013 14967 KI7 013 14968 KT7 013 14969 KT7 013 mm mm mmm mmm mmm MM mmm MM MM mmm mmm MM MM MM MM MM mmm mm mmm MM MM OT Aug O1 06
7. 013 14909 KT7 013 14910 KT7 013 14911 KT7 013 14912 KT7 013 14913 KT7 013 14914 KT7 013 14915 KT7 013 14916 KT7 013 14917 KT7 013 14918 KT7 013 14919 KT7 013 14920 KT7 013 14921 KT7 013 14922 KT7 013 14923 KT7 013 14924 KT7 013 14925 KT7 013 Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim me ee eee ee eee ee A A A A A A A A MA A eee A A ee eee eee eee A A A A 14926 KT7 013 14927 KT7 013 14928 KT7 013 14929 KT7 013 14930 KT7 013 14931 KT7 013 14932 KT7 013 14933 KT7 013 14934 KT7 013 14935 KT7 013 14936 KT7 013 14937 KT7 013 14938 KT7 013 14939 KT7 013 14940 KT7 013 14941 KT7 013 14942 KT7 013 14943 KT7 013 14944 KT7 013 14945 KT7 013 14946 KT7 013 14947 KT7 013 14948 KT7 013 14949 KT7 013 14950 KT7 013 14951 KT7 013 14952 KT7 013 14953 KT7 013 14954 KT7 013 14955 KT7 013 14956 KI7 013 14957 KT7 013 14958 KT7 013 14959 KT7 013 14960 KT7
8. 4922 KT7 000 14923 KT7 000 14924 KT7 000 14925 KT7 000 14926 KT7 000 14927 KT7 000 14928 KT7 000 14929 KT7 000 14930 KT 7 000 14931 KT7 000 14932 KT7 000 14933 KT7 000 14934 KT7 000 14935 KT7 000 14936 KT7 000 14937 KI7 000 14938 KT7 000 14939 KT7 000 14940 KT7 000 14941 KT7 000 14942 KT7 000 14943 KT7 000 14944 KT7 000 14945 KT7 000 Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim Tappet shim mm mmm mmm mmm mmm MM MM MM mm mmm mm MM MM mm mmm mmm mmm MM MM 14946 KT 7 000 14947 KT 7 000 14948 KT 7 000 14949 KT 7 000 14950 KT 7 000 14951 KT 7 000 14952 KT7 000 14953 KT7 000 14954 KT7 000 14955 KT7 000 14956 KT7 000 14957 KT7 000 14958 KT7 000 14959 KT7 000 14960 KT7 000 14961 KT7 000 14962 KT7 000 14963 KT7 000 14964 KT7 000 14965 KT7 000 14901 KT7 013 14902 KT7 013 14903 KT7 013 14904 KT7 013 14905 KT7 013 14906 KT7 013 14907 KT7 013 14908 KT7
9. ached sheet This kit is intended for closed course competition purposes only So take note that it is prohibited to drive your motorcycle on a public road after the installation of this kit O O O O 0 A serial number is stamped on the cylinder head The serial number stamped on the cylinder head is intended for us to manage the production date production lot and the specifications You may be requested in some cases to inform us of the serial number when ordering small parts a serial No is stamped here XY 4 Al Aug O1 06 A CAUTION The following show the envisioned possibility of injuries to human bodies and property damage as a result of disregarding the following cautions o This kit is intended for closed course competition purposes only So take note that it is prohibited to drive your motorcycle on a public road after the installation of this kit Drive your motorcycle at a legal speed abiding by the laws o Make sure the engine and muffler are completely cool at below 35 degrees C before starting the installation Otherwise you will burn yourself o Do the installation with right tools Otherwise breakage of parts or injuries to yourself may take place o As some products and frames have sharp edges or protruding portions please work with your hands protected Otherwise you will suffer injuries o Always use new gaskets and packings The continued use of the worn or damaged ones w
10. ase ix About carburetor o Carburetor setting varies depending on the air funnel air filter specifications and the natural phenomenon like barometric pressure and temperatures So do the setting to match these conditions The wrong air fuel ratio may damage the engine in the worst case xx About ignition system o Only TAKETAWA made and standard ignition systems are compatible Please do not use any other C D I because no data is available with us for us to judge their compatibility Moreover some ignition systems even of TAKEGAWA make are not compatible which please note About inner rotar C D I Not usable Tap for 88cc Tap for 106cc ix About fuel o Be sure to alwavs use premium unleaded petrol ix About overhaul o There is no specific distances traveled before the overhaul It is however advisable to check for the damages on the parts as early as possible Please be informed that specifications design and prices are subject to change without prior notice Wedo not accept any complaint filed with us against any technical trouble caused by the combined use of our parts with other manufacturers parts unspecified by us This manual should be retained for future reference SPECIAL PARTS 3 5 16 Nishikiorihigashi Tondabayashi Osaka Japan TEL 81 721 25 1357 FAX 81 721 24 5059 URL http www takegawa co jp N Installation Procedures N Note A
11. d Hyper CDI High Duty Cam Chain e 4 A2 Au9 01 06 N Z Kit Contents KON ay No Part Name oy TA Camshat intake SiC 20 Sealing Washers E o Cam Gear mak fiz Jom Flange Nuis fa e Center Cam Gear COMP 1 24 Extant Pipe Gasket I o jorerdge SS PI S x TD Socket Cap Screws 4 Ignition Cord Aluminum Special 16 Cable Joint COMP the heat resistant lubricating agent S Inner Parts of Cylinder Head No Part Name 3 vave Spring Seas A 4 Valve Guide Stem Seas 4 5 ess A 76 Vaie Spring Retainers a 7 Mecos Se e famasi a o vale titers Sa b b A4 Au9 01 06 f o Relation between Front Fork and Tire O Upright 27 front fork gold colored bottom case x In case a 10 tire is used clamp the fork and the top bridge at the very tip of the fork o Clamp the fork at the tip of the inner tube but excluding the top bolt portion interfere with each other o Be sure to check for the interference with the fork compressed to a maximum before riding o In case they interfere with each other change the tire with the smaller one silver colored bottom case and upright 27 front fork two piece xx Clamp the fork and the top bridge at the very tip of the fork o Clamp them at the tip of the straight portion o
12. e them o Wipe off the red lead primer on the valve faces and strike the valves once and lightly with the valve punner without rotating them and check the contact surfaces for damages or scratches o Remove the valve and check the contact surfaces for damages or scratches o Check the contacting width of valve seat Service Limit IN EX 1 5mm ix If there is a scratch on the valve seat or the contact width isn t uniform or it is too wide or too narrow modify the seat yx Ask a specialist shop in internal combustion for the modification work Valve Assembly o If you have removed a valve spring seat and valve stem seal install the valve spring seat and a new valve stem seal Note In case you have removed the valve stem seal be sure to replace it with a new one a G B Valve stem seal l wo Valve spring fa l Valve spring seat a Valve spring retainer e Whenever vou fix a valve to the head be sure to applv either engine oil or molybdenum solution to the valve stem o To the head attach the valve spring with a narrower pitch side pointing to the combustion chamber Fix it with the painted portion on the upper side CAUTION Be sure to place the narrowly pitched portion of the valve spring to face the combustion chamber side Painted portion Combustion chamber Narrower pitch o Attach the valve spring retainer o Attach a tappet hole protector to the valve lifter bore
13. er tightening 10 cap screws diagonally in a few steps starting from the inside NNote Be sure to tighten screws to the specified torque T 6 N m 0 6 kgf m IN EX valve clearance 0 15 0 03 mm For 125cc IN valve clearance 0 15 0 02 EX valve clearance 0 15 0 2 0 02 o With a cutter knife cut off the gasket squeezing out of the cylinder head to make the surface flat Note Be careful not to scratch the side cover mating surface o Apply oil to the sliding surfaces of the valve lifter and cam shaft o Degrease well the head cover mounting surface of the cylinder head 4 o Tighten the cam chain guide roller bolt on the cylinder to the specified torque Note Be sure to tighten to the specified torque T 10 NU m 1 0 kgf m o Degrease well the side cover mounting surface o Insert the 7x10 knock pin into the knock hole on the side cover mating surface supplied bridge and apply engine oil to the ues O ring And install the bridge to the cylinder head eega AA and tighten it with the supplied 4x12 cap screw iti lt I i Da NNote Be sure to tighten to the specified torque x T 4 NU m 0 4 kgf m 4 sa K 1 L3 a IT ien PIETA 1 Sw 28 PEER TRUE EN d haha m exhaust sides of the head cover gasket which o Cut off the st
14. etected carry out a shakedown about 150 to 200 km lo After the initial running in check for abnormalities such as abnormal sounds or blow bye lf there is a problem disassemble the engine again to check each part Awarning Never reuse piston pin circulip o Thoroughly wipe off the oil and dirt adhering to Note Determine the heat value of a spark plug the engine depending on how much it is burnt Ai Caution o Install the engine COMP to the frame o Bolts and nuts which were tightened to the Note Be sure to tighten to the specified torque o Referring to the installation manual for the specified torque at the time of engine assembly T 25 N 25 kaf m carburetor kit install the carburetor may get loosened gradually because of the SUNI LINNAS KOAL repeated thermal expansion caused by heated o Attach the drive sprocket engine So periodically re tighten the bolts and A Note Be sure to tighten to the specified torque nuts T 12 NO m 1 2 kgf m Note Be sure to tighten to the specified torque Install a tachometer without fail About upper limit of revolution o The upper limit of the engine revolution is 12 000 rpm Please drive your motorcycle at below 12 000 rpm lt Driving above this revolution is over revving which not only adversely affects the engine but also damages it in the worst case OF Px B4 Aug 01 06
15. f the fork inner tube not at the tapered portion x Before riding be sure to check for the interfrence with the fork compressed to a maximum b O Inverted front fork xx Before riding be sure to check for the interfrence with the fork compressed to a maximum In case a tire of 3 5 10 and a tire of 100 90 10 is used the cylinder head and the tire may interfere with each other at a point where the fork is compressed to a maximum o In case they interfere with each other either clamp them within the range of clamping portion of the front fork where they do not interfere or change the tire with the smaller one ATI Ay wl Unless you wear a helmet in position you will be at high risk of being killed or injured in an accident On the bike a driver must always wear a helmet protective equipment and highly protective clothes O Safety Precautions ir About upper limit of revolution o As the upper limit of revolution is 12 000 rpm drive at below this revolution Driving above this revolution is over revving which not oniv adverselv affects the engine but also damages it in the worst case x About engine oil o Shorten the cycle of engine oil change And we advise you to use high grade engine oil The failure to change the oil not only adversely affects the engine but also damages it in the worst c
16. fler o Tighten each cap screw diagonally in a few steps to the specified torque A Note Be sure to tighten to the specified torque T 6 N m 0 6 kgf m Special clutch 850 cc At oil change 800 cc Dry clutch 800 cc At oil change 750 cc 10W 40 0 15W 50 Multi grade type o Install the drive chain referring to the instruction manual and the service manual for rear swing arm o Lightly apply Aluminum Special the heat resistant lubricating agent to the threaded portion of the spark plug which please install Note Do not make mistakes in selecting the plugs Note Be sure to tighten to the specified torque NGK di x Engine Start o After checking that the ignition key and the gas cock are turned OFF remove the spark plug O Continue kicking the starter for a while to Heat value circulate the engine oil throughout the engine lo Add engine oil as follows AN AN o Screw tight the side bolt on the cam chain tensioner Note Be sure to tighten to the specified torque T 8 N m 0 8 kgf m o Reinstall the spark plug turn ON the gasoline Denso usir ER9 cock and ignition key and start the engine Heat value agape Be sure to tighten to the specified torque T 12 NO m 1 2 kgf m MWarning Do the work in a well ventilated place o Check for any abonormalities like abnormal sounds lo If nothing abnormal is d
17. he position N Caution o When you adjust the valve timing with the head installed to the motorycle valve lifters sometimes fall off at the time you remove the camshaft at the exhaust side If the valve lifters have fallen off detach the head cover and reinstall back the shims and valve lifters at the original positions Valve Timing Adjustment o Set the piston at the top dead center TDC position o Attach the timing protractor to the crankshaft and set the protractor dial at O and tighten the nut Recheck that the piston is at TDC In case it is not right on the TDC adjust it with a pointer Timing protractor Item No 00 01 0062 o Set a magnet base stand so the dial gauge is vertical to the cylinder head valve lifter surface At this point pressing the dial gauge And set the dial at O Use a special rod so the dial gauge rod does not interfere with the camshaft o Rotate the crank shaft counter clock wise viewed at the left side of the engine and read the lobecenter NS 4 C4 Au9 01 06 Honda Made Genuine Shim List Fat uroer Fat Nuber Fat Nuber 14901 KT7 000 14902 KT7 000 14903 KT7 000 14904 KT7 000 14905 KT7 000 14906 KT7 000 14907 KT7 000 14908 KT7 000 14909 KT 7 000 14910 KT 7 000 14911 KT7 000 14912 KT7 000 14913 KT7 000 14914 KT7 000 14915 KT7 000 14916 KT7 000 14917 KT7 000 14918 KT7 000 14919 KT 7 000 14920 KT 7 000 14921 KT7 000 1
18. hickness gauge For example you have got a right valve clearance when you can put in a thickness gauge at 0 15mm but not at 0 18mm Valve Disassembly o Remove the valve lifters and the shims Keep the removed parts in an orderly way so you can see later where to reinstall them back o Attach the tappet hole protector to the valve lifter bore A tappet hole protector is a special tool made by Honda with an item No of O7 gt GME KT70100 o Compress the valve spring using a valve spring compressor Note Do not compress the valve spring more than necessary A valve spring compressor is a special tool of an item No of 00 01 071 made by TAKEGAWA Valve spring compressor o Remove a valve cotter o Remove first the valve spring compressor and then the following U parts H Valve spring retainer D Valve spring Valve Spring Valve Valve cotter Valve spring retainer o Check each valve for bending baking and damages U O0 Measure the exterior diameter of the valve stem at the sliding H surface of the guide with a micrometer Replace bent baked or damaged valves with new ones Service Limit IN EX 3 7 mm Aug O1 06 O Valve Sheet Inspection o Remove carbon sediment in the cylinder head combustion chamber and valve O Dissolve red lead primer with oil or the like and apply it to the valve faces evenly o Strike the valves once and lightly with a valve punner to rotat
19. icking out head cover gasket was attached to the mating surfaces of the head cover and cylinder head and then install the side cover gasket o Attach the head cover to the cylinder head Intake XS a ee QW9 4 side AT ESEE paa ph 1801 S E be EJ 7 SS ra B3 Aug 01 06 o Attach the side cover to the cvlinder head with x 12V motorcycle o Install the generator cover nine 5x22 and two 5x15 cap screws See the o Here the work needs to be done to extend the Note Be sure to tighten to the specified torque foto below ignition cord Cut off the ignition cord about 10 cm T 70 11 NU m 0 7 L 1 1 kgf m Lightly apply Aluminum Special the heat from the ignition coil Cut the supplied cord at a de In the case of a three point support bearing resistant lubricating agent to the threaded point after fixing how to route the supplied cord crankshaft referring to the installation manual portion of the screws ANNote Be sure to fit the screws in the right positions and connect the cord with a supplied cable joint in the following way for the crankshaft kit install the generator cover Cable joint Ignition coil ejim Screw cap Plastic sleeve Rubber sleeve o Attach the supplied plug cap to the ignition cord o Referring to the installation manual for the i exhaust muffler install the exhaust muf
20. ile riding immediately stop riding and park your motorcyle in a safe place to check what has gone wrong Otherwise the abnormality could lead to accidents o Before riding be sure to check every section for slack in parts like screws lf you find slack ones screw them securely up to the specified torque Otherwise improper tightening may cause parts to come off leading to accidents o Check or carry out maintenance of your motorcycle correctly according to the procedures in the instruction manual or service manual Improper checking or maintenance could lead to accidents o Fuel must be high octane gasoline Otherwise troubles such as engine knocking may cause accidents Compatibility Sheet Front Fork Standard or Stock Fork ND p 27 Upright Fork for 8 Two Piece TAKEGWA adel Yes L L l 01 L 17 p 27 Upright Fork for 10 Two Piece TAKEGWiA nade Yes Yeso Yes Ys Ys p 30 Upright Fork TAKE rade Yes J es J Ves Yes Ves f Inverted Fork TAKE nade o f Yes J Ves Yes se pp A5 About oil cooler stay A conventional oil cooler stay to be attached to the frame cannot be installed Please use an oil cooler kit to be attached in front of the fork using a TAKEGAWA made steering stem Engine Specifications of Our Recommendation MIKUNI VM 26 03 05 047 Clutch Dry Special Clutch of TAKEGAWA make Wet Special Clutch of TAKEGAWA make ignition System Standard Generator Standar
21. ill cause engine trouble The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the WARNING 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 subsequently to accidents o Before doing work make sure your motorcycle is secure on level ground for safety s sake Otherwise your motorcycle could overturn and injure you while you are working o Always start the engine in a well ventilated place and do not turn on the engine 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 Since vaporized accumulation of gasoline is at high risk of explosion work in a well ventilated place Otherwise it may cause a fire o Always use a torque wrench to screw bolts and nuts tight and securely to the specified torque Otherwise these parts may get damaged or fall off resulting in accidents 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 an accident o When you notice something abnormal with your motorcycle wh
22. lways use a torque wrench to screw parts tight and securely to the specified torque AN Warning This Installation Instruction is prepared for those who have acquired basic skill and knowledge Therefore those who are technically inexperienced or unskilled are requested not to do the installation work Warning Never reuse the used piston pin circlip o Hold the cam chain so it does not fall into the o Tighten the cylinder bolt to the specified torque crankcase Note Be sure to tighten to the specified torque T 12 N m 1 2 kgf m o Check the kit contents o Prepare necessary tools o Referring to the Installation Procedures for a piston cylinder kit install the cylinder o Insert the supplied 8x14 knock pins into the cylinder f t o Attach the supplied new copper sealing washer and washer o Apply engine oil to the bearing of the supplied a apm Note Be careful where to attach the copper idle gear tha mh A z sealing washer o Degrease the upper surface of the cylinder thoroughly Note Be careful not to scratch the upper surface of the cylinder o Attach the supplied cylinder head gasket to the cylinder o Aligning the notch on the cylinder head with the alignment mark small one on the idle gear attach the camchain to the idle gear sprocket and install the idle gear using an idle gear shaft
23. nd nuts tight and securely to the specified torque You cannot do the work without the torque wrench Please never use these kits in combination with other manufacturers parts Install a tachometer in order to always drive your motorcyle at below the specified engine revolution Be sure to always use premium unleaded petrol Please note that because of the improvement to the kit the contents of this manual or specifications will be changed without prior written notice This kit is applicable only to CDI ignition type vehicles and is not applicable to point ignition type vehicles And please never use other ignition systems than TAKEGAWA s o We do not take any responsibility for any accident or damage whatsoever arising from the use of the kit not in conformity with the instructions in the manual We shall be held free from any guarantee or compensation whatsoever of any technical trouble caused by the combined use of our products with parts not specified by us 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 O O O O O O O O O A muffler for the Monkey or Gorilla cannot be installed Please note that we shall be held harmless from any guarantee of any parts other than ours if technical trouble occurs after the installation of this kit A special exhaust pipe for the exhaust muffler is available from us Please purchase the one referring to the att
24. ve punner or valve lap to remove valve lifters O When you cannot easily remove shims use a a pair of tweezers or magnet H Keep the removed lifters and shims in an orderly way so you can see where to reinstall them back O Be sure to reinstall back the valve lifters at its original place How to figure out a size of new shims O Wipe off oil adhering to the shims Measure the thickness of the shims with a micrometer and take a note of it H U Thickness of the shims to be figured out O O The valve clearance measured O O The valve clearance to be measured H O The thickness of the shim removed U0OUL ULOUL Cl Aug 01 06 a The shim is set at 1 20 mm to 2 9 mm evenly spaced at 0 025 mm apart ix Though the shim is available from us a Honda s genuine one is also compatible For its part No please see the attached sheet 1 825mm 1 85mm 1 875mm Be sure to check the size of new shims with a micrometer whether Honda made genuine shims or not it is correct Valve Lifter Installation o Attach the new shims to the valve spring retainer o Degrease the valve lifter and blow air into the shim mounting portion of the valve lifter to clean the portion o Apply molybdenum disulfide solution to the sliding surface of the valve lifter and attach it N Note Be sure to install back the lifter in its original location o Attach the camshaft and check the valve clearance with the t
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