Instruction Manual for ST-3 Super Head Cylinder Kit
Contents
1. temNo QOO 0O0 0000 Fitting Ape Ape100 XR50 Motard and XR100 Motard Specification Compatible with a motorcycle equipped with a TAKEGAWA s ST 3 Super Head Thank you for purchasing one of our TAKEGAWA s products These products are a cylinder and a piston kits for our Stage 3 super head We have designed the cylinder with an aluminum oil passage So you can install an oil cooler Moreover we have also designed the piston to be light in weight and given molybdenum coating to the skirt for better comformability Please strictly follow the following instructions in installing and using the kit Please read the following before starting the installation O This kit alone cannot function on its own So you are required to purchase the special cylinder head and the recommended parts 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 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 For the purpose of using this kit in Ape50 and XR50 Motard our TAKEGAWA made Stage 3 super head and stroke up crankshaft kit are necessary O This kit is for exclusive use with our TAKEGAWA made Stage 3 super head In case this kit is to be used in Ape50 and XR50 Motard the crankca2. for future reference J A1 Aug 22 06 Kit Contents No Part Name Oy Repar Part Jin packs of 3 Pinson Ring Set too Ca Piston Pin pme j 5 Pison Pin Cicip Hrn A 6 Cyirder Head Gaska 1 earen O 7 feiers a ee e Auminum Sealing Washer 2 00700 w o for Pug Bot 2 posero No emio Description e preo Gasket KE x 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 J Va yx Processing to crankcase In case of installation to a 50cc motorcycle disassemble the engine referring to the service manual and consult your specialist shop for the processing Install the crankcase referring to the Honda s service manual and the installation instructions for a stroke up crankshaft kit A Note Be sure to tighten to the specified torque Note Always use the new gaskets x Cylinder Installation lt Remove the gasket scraps thoroughly with a scraper ora cutter knife AS Note Be careful not to give scratches to the clamp face With a cutter knife cut off the gasket squeezing out of the crankcase sleeve hole so the sleeve hole surface becomes le
3. o 14 002 14 008 mm 13 9940 14 000 mm Top 0 15 0 38 mm 2nd 0 20 0 45 mm Oil 0 20 0 70 mm 0 05 mm 57 095 mm 56 95 mm 14 03 mm 13 98 mm 0 50 mm 0 50 mm 0 90 mm a e 0 10 mm 0 0020 0 014 mm 0 05 mm Middle Bottom i N Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Tan Aug 22 06 About boring process of a crankcase Installation of the provided cylinder to Ape50 and XR50 requires crankcase processing Io those who have the crankcase boring processed by a specialist shop Bore the crankcase till it is 61 4 mm in diameter and 25 5 mm in depth with crankcase gaskets put in between And in processing the crankcase take care to keep the walls of a dowel pin hole and an oil passage hole as thick as possible Over processing will result in hardness decrease and poor oil lubrication Dowel pin hole OOU 00 Gasket aco O gora 6 A iad O UOU 00 UU 00 Dowel pin hole HO o00 Cautions Please note that processing of the crankcase will thin the wall thinkness leading to strength degradation SPECIAL PARTS WeN4SeYWYA Co Ltd 3 5 16 Nishikiorihigashi Tondabayashi Osaka Japan TEL 81 721 25 1357 FAX 81 721 24 5059 URL http www takegawa co jp A Apr 09 12
4. all the piston to the cylinder with care so the piston ring end gaps do not get out of alignment Once the nision is completely in the cylinder pass the cam chain through the cylinder and install the eying to the crankcase Remove the waste cloth used to clog Fix the cam chain guide aligning the holes Degrease the mating surfaces of the crankcase and the cylinder with thinner or the like Attach two dowel pins and a cylinder gasket to the crankcase Apoy engine oil to the inside of the cylinder and then spread the oil evenly its end with the grooves on the crankcase and its protrusion with the grooves on the cylinder In the case of a 50cc motorcyle install the cam chain guide supplied in the crank kit Protrusion Cam chain guide S Crankcase Lox Install the cylinder head referring to the cylinder head installation instructions P B1 Aug 22 06 f Description Intemal Diameter of Pin Hole Extemal Diameter of Piston Pin Clearance of Piston Ring End Gap Clearance between Cylinder and Piston Clearance between Piston and Pin Inspection of Cylinder O Check the inside of the cylinder for wear and damage Measure and take note of the internal diameters of the cylinder at 6 positions at the piston pin angle and at the right angle to it X Y each at upper mi
5. ation with right tools Otherwise breakage of parts or injuries to yourself may take place As some products and frames have sharp edges or protruding portions please work with your hands protected 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 WARNING 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 Always use new piston pin circlips gaskets and packing The worn or damaged parts may break the parts leading to accidents 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 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 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 Before riding always check every section for slack in parts like screws If you find slack ones screw them securely up to the specified torq
6. ddle and lower parts Treat the measured largest value as its internal diameter If the diameter is larger than 57 095 mm replace the cylinder Figure out the clearance between cylinder and piston Inspection of Piston O Clear the piston of the remaining carbon residue Fit a piston ring into the piston and measure the clearance between the piston ring and ring groove with a thickness gauge with a piston ring being inserted into the ring groove lt If the clearance is larger than 0 17 mm replace the piston Check the outside of the piston for the damage O 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 lt If the diameter is smaller than 56 95 mm replace the piston O Measure the internal diameter of the piston pin hole lt If the diameter is larger than 14 03 mm replace the piston Figure out the clearance between the piston and piston pin O Inspection of Piston Ring Insert each piston ring into the cylinder from the bottom And measure the clearance of the end gap with a thickness gause Service limit If the clerance is more than 0 5 mm at top and 2nd or more than 0 9 mm at oil change the piston ring f Reference Value List for Cylinder and Piston Cylinder Distortion Intemal Diameter o 57 57 000 57 020 mm Extemal Diameter 9 mm from the lower edge of the skirt 56 970 56 995 mm
7. se needs to be processed in the portion where a sleeve is to be attached For the details and enquiries please consult with your local specialist shop handling internal combustion products or a motorcycle dealer The processing of the crankcase requires engine removal and mounting crankcase disassembly and other work Please do the work correctly referring to a HONDA genuine service manual for your vehicle In addtion you need to prepare gaskets and the like for the assembly which please purchase separately Please be informed that we shall be held harmless against any claim against us whatsoever arising out of use of the products in closed course competition 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 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 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 install
8. ue Or improper torque may cause parts to come off leading to accidents O When you notice something abnormal with your motorcycle while 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 As gasoline is highly flammable never place it close to fire Make sure that nothing flammable is near the gasoline Otherwise it may cause a fire 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 Never use any other parts than those specified by us The use of the unspecified parts may lead to parts breakage and consequent accidents 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 Since vaporized accumulation of gasoline is at the high risk of explosion work in a well ventilated place Be sure to always use premium unleaded petrol Please be informed that the product specifications design and prices are subject to change without prior notice Please be informed that 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 e This manual should be retained
9. vel Left crankcase Right crankcase After correction mi Fix a supplied piston pin circlip to one of the piston pin holes Cylinder Installation Instructions S With reference to the figure below o Insert the cam chain tensioner into Apply engine oil to the entire side surface of the piston and piston rings fix piston rings with a letter N facing upward Color of the piston rings Top Gold 2nd Black Apply engine oil to the piston pin holes Apply engine oil to the piston pin hole of the con rod Apply engine oil or molybdenum solution to the piston pin and fix the piston so EX mark on the upper surface of the piston faces the exhaust side Fix the Supplied piston pin circlip x Arrange the position of the ring end gap of the piston pin circlip not to be on the notch lt Place the cam chain tensioner so the supplied cylinder and hang the hook of the spring on the cylinder In the case of a 50cc motorcycle attach the cam chain tensioner supplied in the crank kit a the tip of the rod will be nearly at the same level as the clamp face Fix it with an adjusting bolt and tighten a locking nut Inst
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