Instruction Manual for Stroke Up Crank Kit for Exclusive Use with
Contents
1. N Instruction Manual for Stroke Up Crank Kit for Exclusive Use with Our TAKEGAWA Made Bore Up Kit 48 5mm Stroke Item No 0 00 00 000 0O Stroke Up Crank Kit Compatible Models and Frame Nos Ape100 HC07 1000001 XR100 Motard HD13 1000001 XR100R O HEO3 2100001 CRF100F O HEO3 2400001 O Thank you for purchasing one of our TAKEGAWA made products Please strictly follow the following instructions in installing and using the kit 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 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 inexperienced or without righ2. 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 installed 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 TAKEGAWA made Bore Up kit will have a remarkable effect increasing the engine displacement to 124 cc from 115 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 bre
3. work in a well ventilated place Otherwise it may cause a fire Cautions Before Running Qhers On fuel Oil Cooler Whenever regular gasoline is left in the fuel tank always replace it with The installation of this kit increases 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 With this kit installation a centrifugal filter will become unavailable So please install an external general purpose oil filter Item No 001 16 001 Change of sprocket The installation of this kit increases the power So the continued use of a Thermometer stock sprocket will result in severe wears of parts because of too low A stick type thermosensor can be fixed on the supplied cylinder side gear not only adversely affecting the engine life but also possibily In addition the following meters can be installed as well breaking the engine in the worst case Therefore please change the 1 A medium LCD Tachometer amp Thermometer 009 05 0141 max reading sprocket with the high geared sprocket of 150 C Engine Parts Recommended by TAKEGAWA O A Digital Thermometer 007 04 0011 max reading of 99 C X This kit is only compatible
4. with those engine parts recommended by us So please replace the engine parts not recommended by us with those of Upper Limt of Revolutions our recommendations The upper limt of revolutions varies depending on the installed cylinder you drive the engine at revolutions below the upper limit Super Head Bore Up Kit ali gt Take note that idling and sudden acceleration particularly in the 1st or 2nd head and camshaft Please install a revolution counter to make sure that uper Head Bore Up Kit ST 2 uper Head Bore Up Kit ST 3 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 Clack ee co aron Sa Ol Pump Super Oil Pump Kit Kit Contents HOUOUU00 Crankshaft for Repairing No PartName Oty Repair Part Item No lt Please order repair parts by indicating the Repair Part Item No Crankshaft COMP O 01 10 0111 as listed above In some cases we may not be able to accept your Woodruff Key O J00 10 0007 orders for a single item out of the kit components In this case Crankcase Gasket J 11191 KN4 T00 please order the required parts in the number mentioned on the Right Crankcase Gasket __ 11393 GCR 100 right half side of the list No Part Name J Qty Repair Part tem No A Radial Ball Bearings
5. 2 63 22 B Timing Sprocket 1 00 10 0009 SPECIAL PARTS UNLEY MNA 3 5 16 Nishikiorihigashi Tondabayashi Osaka Japan TEL 81 721 25 1357 FAX 81 721 24 5059 URL ee Sep 12 06 Installation Procedures Removal Referring to the service manual demount an engine from the body Uncover the generator detach a cylinder head cylinder and piston a i S z Kr J Referring to the service manual detach a clutch shift drum stopper shift drum stopper plate primary drive gear and oil pump When detaching a primary drive gear nut be careful not to lose an oil through pin O Referring to the service manual O Detach a kick starter spring and O Slide the camchain away from spring collar z Unfasten a flange bolt holding a crankcase tool Tap the crankcase with a plastic hammer to separate it D Right crankcase A O Remove a kick starter spindle O Detach a main shaft and counter shaft O Detach a stud bolt guide plate sprocket to detach the crankshaft necessary remove a transmission and other parts shift fork shaft and shift fork generator and parts Have the crankcase processed by a motorcyle specialist shop For details please refer to the attached sheet Installation O Clean the bored crankcase in case the crankcase is bored O Apply engine oil to the bearing
6. akage in the worst case Please be informed that mainly because of improvement in performance design changes and cost increase the product specifications and prices are subject to change without prior notice This manual should be retained for future reference AN 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 Always try to drive your motorcycle at a legal speed on the public road abiding by the laws 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 d
7. amage If you find worn or damaged parts replace S them with new ones yy Al Sep 12 06 ie The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the 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 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
8. nal diameter at the small end of the con rod If larger than 14 05 mm replace it Measure the clearance at the big end of the con rod in the axial direction If larger than 0 6 mm replace it 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 If larger than 0 01 mm 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 Measure the deflection of the crank shaft On the right side Replace the crankshaft when the deflection p ee x a mm Qj 0 008 mm 0 1 0 35 mm 0 035 mm 0 020 mm Tapered surface Replace Replace Replace Replace Replace Replace Replace Replace exceeds 0 085 mm fy J pas On the left side Replace the crankshaft when the deflection x j exceeds 0 070 mm m g ad of a mT i SI Left side Rightside UOUU UOUU Sep 12 06
9. ote Be sure to tighten to the specified torque Torque 64 N jm 6 5 kgf m FU n gt A i Cut with a cutter the mating surfaces of the cylinder to be flat _ Be careful not to let any gasket chips get into the crankcase i 3 Eg i Ar gt f sic Sea a l a ES i sT O Slightly apply grease to the lip of an oil seal of the clutch cover and then d D jes attach a clutch case cover Apply ZX E the aforesaid Aluminum Special a i little to the threaded portion of the bolt on the outside of the case And tighten them to the specified torque A Note Be sure to tighten to the specified torque Torque 10 N Jm 1 0 kgf m a Referring to the installation procedures for the cylinder install the cylinder Sep 12 06 N Reference Value List for Crank Shaft Maintenance f Intemal diameter of con rod at small end Clearance between con rod s small end and a pin Misalignment on con rod s big end longitudinal and transversal direction Side clearance Free play on the joumal beanngs in the direction of shaft in the direction of bearings on the nght side on the left side Crank shaft deflection Inspection of Crank Shaft O Check the crank shaft for damages on the flywheel mounting surface If there is a damage replace the flywheel and the crank shaft O Measure the inter
10. s 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 shn a U a gt O Apply engine oil to the bearings in the supplied crankshaft Attach the crankshaft to the case passing the crankshaft through a camchain E a ee a ote O Attach two stock dowel pins to the crankcase O 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 Sep 12 06 I Set the position of the right O Install a shift drum stopper plate and O Install an oil pump O If a stator base is removed crankcase and install it shift drum stopper which please tighten to the specified torque A Note Be sure to tighten to the specified torque Torque 12 N jm 1 2 kgf Jm Bolt for drum stopper plate Er elr tF and tighten to the specified torque Note Be sure to tighten to the specified torque Torque 10 N jm 1 0 kgf m 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 Jer Oil through pin O Apply engine oil to the threaded portion and seating face of the primary drive gear nut which please install and tighten
11. t 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 this kit on the point ignition system motorcycle Please be informed that what we can safely say is that the ignition system is compatible only with ours and stock ones because no data is available with us on the compatibility with other ignition systems Therefore please never use other ignition systems which may cause technical troubles 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
12. to the specified torque Spring collar Put a pin into the shift drum A Note Be sure to tighten to the specified torque Torque 39 N m 4 0 kgf Jm 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 A Note Be sure to tighten to the specified torque ao i M NREN e a L e e o M M E E E E E E E E E E E E E E E E E E E E E E E E E M cision SS ETE w y 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 A Note Be sure to tighten to the specified torque Torque 10 N jm 1 0 kgf m 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 Wire up a neutral lamp the screen Degrease well the tapered Degrease well the mating surfaces surfaces of the crankshaft and of the clutch case and attach two flywheel And attach the supplied dowel pins to the case woodruff key to the crankshaft WwW p a and then a flywheel Tighten the f A flywheel nut to the specified torque A N
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