146cc strokers crank kit. Installation manual.
Contents
1. 146cc strokers crank kit Installation manual D 48 5mm Stroke Super Head R For only 146cc SCUT cylinder Thank you for purchasing one of our products Please strictly follow the following Item No 0 00 00 000 For SCUT only instructions in installing and using the kit Compatible Models and Frame Nos O Before installing the kit please be sure to check the kit contents Should you have any questions about the kit please contact your local motorcycle dealer a eiA Hare aaah Please note Illustrations and photos may vary from actual hardware XR100R HEO3 2100001 CRF100F O HEO3 2400001 Read all instructions first before starting the installation 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 Please note that this kit is designed for exclusive use in the above mentioned compatible models and frame numbers only and that it cannot be mounted on other models Installation of this kit requires removal and mounting of an engine and crankcase disassembly We strongly recommend you to work strictly following a HONDA genuine parts service manual for your vehicle with enough care Besides this instruction manual as well as the HONDA service manual is prepared for those who have acquired basic technical skill and knowledge Therefore we recommend those who are technically inexperience2. please install and tighten to the specified torque Spring collar Put a pin into the shift drum A Caution Apply the specified torque Torque 39 N m 4 0 kgf m It is advisable to use a con rod stopper or gear holder O Referring to the service manual or to the installation procedures for the clutch kit install a clutch slightly apply grease to the lip of the oil seal on the stator base And apply oil to the O ring and attach it to the crankcase torque Torque 10 N Jm 1 0 kgf m A Caution Apply the specified torque Torque 10 N jm 1 0 kgf m O Install a stator coil Please clean the screen before installing it In the worst case the engine may burn out if the oil cannot pass through the screen because of the accumulated dirt or dust on the screen Degrease well the mating surfaces of the clutch case and attach two dowel pins to the case a V Wire up a neutral lamp Degrease well the tapered surfaces of the crankshaft and flywheel And attach the supplied woodruff key to the crankshaft and then a flywheel Tighten the flywheel nut to the specified torque torque Torque 64 N jm 6 5 kgf Jm O A Caution Apply the specified PA Q b pin O Cut with a cutter the mating surfaces of the cylinder to be flat Be careful not to let any gasket chips get into the crankc
3. 085 mm If there is a damage replace the flywheel and the crank shaft lt If larger than 0 01 mm replace it On the left side Replace the crankshaft when the deflection exceeds 0 070 mm Tapered surface A 0 Measure the internal diameter at the small end of the con rod If larger than 14 05 mm replace it O Measure the clearance at the big end of the con rod in the axial direction O Measure the misalignment on the journal bearing of the crank Le If larger than 0 5 mm replace it shaft 00o UOUUU Shaft direction If larger than 0 10 mm replace it Bearing direction If larger than 0 05 mm replace it Left side Rightside Cylinder edge aie Mer 24 11
4. ase EN d p O Referring to the installation procedures for the cylinder install O Slightly apply grease to the lip of an oil seal of the clutch cover and then attach a clutch case cover Apply the aforesaid Aluminum Special a little to the threaded portion of the bolt on the outside of the case And tighten them to the specified torque A Caution Apply the specified torque Torque 10 N Jm 1 0 kgf m the cylinder Mar 24 11 INSPECTION SERVICE LIMITS Intemal diameter of con rod at small end 14 05 mm Replace Clearance between con rod s small end and a pin 0 012 0 036 mm 0 09 mm Replace Misalignment on con rod s big end longitudinal and transversal direction aa 0 01 mm Replace Side clearance _ 0 5 mm Replace Free play on the joumal bearings in the direction of shaft _ 0 1 mm Replace in the direction of bearings 0 05 mm Replace Crank shaft deflection on the nght side 0 085 mm Replace on the left side 0 070 mm Replace Inspection of Crank Shaft O Measure the misalignment at two points at the big end of the O Measure the deflection of the crank shaft Check the crank shaft for damages on the flywheel mounting con rod at right angles to the shaft as shown in the figure on On the right side Replace the crankshaft when the surface the right deflection exceeds 0
5. d or without right tools to ask a technically trustworthy specialist shop to do the work We shall be held free from any responsibility or compensation whatsoever for any glitch in the parts other than ours if the glitch takes place after the installation and use of the kit If you make modifications to any product of the kit we shall be held free from any guarantee of the product You are kindly requested not to contact us about the combination of our products with other manufacturers Always use new bolts nuts dowel pins and packings Never reuse severely worn out or damaged ones Do not use liquid packings which may oppilate oil s passage it may break the engine in the worst case 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 remains in the fuel tank always replace it with high octane gasoline Never use on contact breaker point ignition Applicable ignition system for stock Honda CDI or our CDI system Never use with other manufactures ignition system With this kit installation a stock crankshaft will be removed which means a loss of a centrifugal filter So please install an external oil filter Install an oil cooler when necessary Engine oil must be API SF or of a higher class such as SAE 10W 40 15W 50 which are our recommendations The upper limit of revolutions varies depending on the in
6. e 1 WARNING following cautions 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 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 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 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 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 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 Cautions Before Running Others On fuel Oil Cooler Whenever regular gasoline is left in the fuel tank always replace it with The installation of this kit increase
7. ible with those engine parts recommended by us So please replace the engine parts not recommended by us with those of our recommendations Bore Up Ki il Pump Heavy Duty 5 Disk Clutch Kit Ignition System SS Outer Rotor Kit Hyper C D I C D I Magnet Kit Kit Contents 00 00 u 000 Crankshaft for Repairing No PatName Qty Repair Part item No No Part Nare Qy Repair Part tem No Oty 1 Crankshat com f a ooro OO 2 wodu Ky o ooon B Timing Spoke 1 ooro 1 3 Crankcase Gasket 0 MIKN O 4 Right Crankcase Cover Gasket 1 11393 GCR TO1 x Please order repair parts with the Repair Part Item No Without the repair part item No we may not be able to provide the correct parts Some parts are only available as a set Please order them with the set number Va A2 Mar 24 11 Installation Procedures Removal O Detach a kick starter spring and O Slide the camchain away from Installation spring collar sprocket to detach the crankshaft O Apply engine oil to the bearings in the crankcase O Reinstall those parts detached at the time of crankcase boring O Install the transmission referring to the service manual or to the installation procedures for the transmission Referring to the service manual demount an engine from the body Uncover the generator li necessary remove a transmis
8. s the heat release value of the engine high octane gasoline set off by the increase in power For a long time high load running we recommend you to install an oil cooler kit which keeps the oil at appropriate temperatures and prevents such troubles as lack of oil film at high temperatures But this doesn t apply to XR100R and CRF100F To use this crank kit Centrifugal Oil Filter Rotor are not used please equip other type of oil filter such as our special clutch cover with filter Change of sprocket The installation of this kit increases the power So the continued use of a stock sprocket will result in severe wears of parts because of too low gear not only adversely affecting the engine life but also possibily breaking the engine in the worst case Therefore please change the sprocket with the high geared sprocket Upper Limt of Revolutions The upper limt of revolutions varies depending on the installed cylinder head and camshaft Please install a revolution counter to make sure that you drive the engine at revolutions below the upper limit Take note that idling and sudden acceleration particularly in the 1st or 2nd gear tend to exceed the upper limit of revultions Over revolutions will result in nonsmooth revolutions of the engine not only adversely affecting the engine life but also possibily breaking the engine in the worst case Recommended engine parts X This kit is only compat
9. sion and other parts O Apply engine oil to the bearings i the supplied crankshaft O Unfasten a flange bolt holding a crankcase k s a O Attach the crankshaft to the case passing the crankshaft through a camchain ad 4 a _ d ait pi amp oF 4 Attach two stock dowel pins to the crankcase detach a clutch shift drum stopper shift drum stopper plate primary drive gear and oil pump yy rm yas Tap the crankcase with a plastic hammer to separate it Degrease well the mating surfaces of the crankcase attach the provided new crankcase gasket and apply engine oil to the moving parts in the case Right crankcase When detaching a primary drive gear nut be careful not to lose an oil through pin R i CR ees B1 Mar 24 11 shift drum stopper which please tighten to the specified torque torque Torque 12 N Jm 1 2 kgf m 6 Bolt for drum stopper plate BY el a flange bolts which please attach and tighten to the specified torque A Caution Apply the specified torque Torque 10 N jm 1 0 kgfm O Attach a collar and kick starter return spring Spring O Attach to the crankshaft the collar primary drive gear lock washer and oil through pin Primary drive gear 1 Fa O Apply engine oil to the threaded portion and seating face of the primary drive gear nut which
10. stalled cylinder head and camshaft Please install a revolution counter to make sure that you drive the engine at revolutions below the upper limit Change the sprocket with the one which meets the output and specifications This kit cannot perform on its own This kit is only compatible with those engine parts recommended by us So please replace the engine parts not recommended by us with those of our recommendations Installation of this product requires a left side crankcase cover gasket HONDA s item No 11394 KN4 750 which please purchase additionally Since this kit is designed and developed for driving in closed races do not use the kit for running on the public road Features O The combined use of this kit with the our Cylinder head kit Cypender kit will have a remarkable effect increasing the engine displacement to 146 cc from 100 cc O Crank shaft is made light in weight with the introduction of the balance cut aimed at achieving less vibration We have applied welding to the crank pin in addition to usual press fit assembly in order to reduce vibrations Jump Starting and Sudden Acceleration Please note that idling sudden acceleration and sudden engine braking will put a heavy load on the engine It may result in crank shaft damage and engine breakage in the worst case Please be informed that mainly because of improvement in performance design changes and cost increase the product specifica
11. tions and prices are subject to change without prior notice This manual should be retained for future reference CAUTION The following show the envisioned possibility of injuries to human bodies and property damage as a result of disregarding the following cautions O Since this kit is designed for driving in closed races do not use the kit for running on the public road O Work only when the engine and the muffler are cool Otherwise you will burn yourself O Do the installation with right tools Otherwise breakage of parts or injuries to yourself may take place 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 AS some products and frames have sharp edges or protruding portions please work with your hands protected Otherwise you will suffer injuries 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 leading to accidents Always use new gaskets and packings And check those parts to be reused for wear and damage If you find worn or damaged parts replace them with new ones Ss o Al Nar 24 11 ie The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding th
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