Racing Crank shaft Kit Instruction Manual
Contents
1. N Racing Crank shaft Kit Instruction Manual Stroke 39 mm Item No 0 0 O0 0 0 0 0 0 O For SCUT only Applicable Models and Flame No Monkey Gorilla Z50J 2000001 AB27 1000001 1899999 O Thank you for purchasing one of our products Please strictly follow the following instructions in installing and using the products Before fitting the products please be sure to check the contents of the kit Should you have any questions about the products please kindly contact your dealer Please note Illustrations and photos may vary from actual hardware Please read the following before starting the installation Need the special tool to install crankshaft We shall be held free and harmless from any and all liabilities or claims for any accidents or damages whatsoever arising from the use of the products not in conformity with the instructions in the manual This kit is designed for exclusive use in the above mentioned applicable models of motorcycles and frame numbers only Please take note that this kit cannot be mounted on other types of motorcycles Installation of this product requires removal and installation of an engine and disassembly of a crankcase Please prepare HONDA s service manual for an above mentioned applicable vehicle and work with enough care following the instructions in the service manual Besides this instruction manual as well as HONDA s service manual is prepared fo2. Apply engine oil to a big end of crank shaft of the kit and to the bearing De E O Detach a stud bolt from the crankcases O Enlarge orifice diamter of the right crankcase referring to the instruction manual for a super oil _ see TE Installation Procedures O Fix a gasket of the kit and dowel OWhen installing the gasket please remove the excess if necessary x Be careful not to get any gasket chip in the crankcase pins into the crankcase install the right side crankcase O Install the transmission related parts on the left side see the instruction manual O After applying enclosed the Alumi Special paste to the threaded portion of the crankcase bolts install the bolts onto the crankcase and tighten them diagonally to the specified torque O Install the oil filter screen and install Super Oil Pump see the instruction manual specified torque Torque 10 N jm 1 0 kgf m q see the instruction manual 4 W PA O Being careful of the d gear shaft drum washer tighten shift drum bolts to the specified torque with a hex bolt And attach a rubber plug A Caution Be sure to follow the specified torque Torque 12 N m 1 2 kgf m O Install a clutch Sep 28
3. 11 Cine you remove stud bolt Degrease well the tapered section 3z Precautions to take when yx Special Tools gt on the flywheel and attach the aa flywheel Apply screw locking agent pecial paste to the threaded a little to an M10 flange nut and O When removing the flywheel with a part of the stud bolts attach stud flywheel puller it is advisable to use bolts to the crankcase and tighten a puller adapter in order to protect them to the specified torque Fix Caution Be sure to follow the the crankshaft end as shown in the removing the flywheel Con rod stopper Item No 00 01 01 O After applying the Alumi screw it up to the specified torque the stud bolt B the shorter stud specified torque fig below bolt to the clutch side Torque 54 Nim 5 5 kgfm Use special tool 00 01 031 mene pe y Recommended screw locking agent flywheel puller f LOCTTE 243 Crankshaft Puller adapter Lock nut wrench ltem No 00 01 021 for 12 7 mm 1 2 00 01 022 for 19 5 mm 3 8 Flywheel puller i gt LE r3 i O Fit the cam chain into the crank Install the cylinder Flywheel shaft and attach a tensioner roller see the cylinder kit instrallation via ee procedures O Attach a cylinder head following the installation procedures of the cylinder head Apply Alumi Special to the bearing supporting section at the end of the crank shaft
4. Referring to the service manual fix a drive chain Install generator cover with specified torque Flywheel puller Item No 00 01 031 of TWIT A Caution Be sure to follow the specified torque Torque 10 N jm 1 0 kgf m Universal holder Item No 00 01 1002 O Install a generator plate and tighten the flat screws Crank shaft amp installer Item No 00 01 1008 oF Puller adapter Item No 00 01 1027 O Pour the engine oil up to the level specified by the clutch kit O Fix the woodruff key to the crank shaft Alumi special 5 g Item No 00 01 0001 5 Sep 28 11 INSPECTION SERVICE LIMITS Intemal diameter of con rod at small end 14 05mm Replace Clearance between con rod s small end and a pin 0 0030 0 018mm 0 035mm Replace Misalignment on con rod s big end longitudinal and transversal direction Of 0 012mm 0 05mm Replace Side clearance 0 6mm Replace or modify Free play on the joumal bearings in the direction of shaft 0 1mm Replace in the direction of bearings a 0 05mm Replace Crank shaft deflection 0 1mm Replace or modify Warning The unskilled or those without proper knowledge are requested not to do the installation work O Inspection of Crank Shaft O Check the crank shaft for damages on the f
5. cing and the like This manual should be retained for future reference Cautions before riding Fuel requirement Use high octane gasoline ONLY Be careful not to remain the regular gasoline Engine parts of our recommendation X This kit is compatible with the engine parts of our recommendations only Therefore please replace with our recommended engine parts Recommended parts Cylinder head DOHC Cylinder head Super head R Super head R O O Cylinder Super head R 100cc SCUT Cylinder 01 04 0123 X The old type inner rotor C D I CANNOT be used Not usable Usable Only one tap for installation NEVER use an old type base plate a Please replace it with the one of our recommendations to avoid any troubles Tap for 88 Tap for 106 About the case of using 5 speed transmission In case you install a 5 speed transmission kit and your kick starter spindle is type A make sure to change the spindle to type B spindle This will improve the efficiency in transmitting the torque at the time of kick start and reduce the load on the gear which will lead to the prevention of gear breakage Type A Kick starter pinion Kick starter pinion It is necessary to change a kick starter pinion Type B as well at the time of changing the kick starter spindle type B Change it with the right one with the number of teeth to match the transmission n ype B kick starter spindle kit 02 04 0011 kit P
6. ems Therefore please never use other ignition systems which may cause technical troubles Install an oil filter outside Engine oil must be API SF or higher class such as SAE 10W 40 15W 50 which are our recommendations 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 Some parts need to be tightened with different torque from the one for genuine parts Be sure to follow this Instruction Manual Use only for a crankcase without modifying Or we recommend our Special Crankcase Kit 01 00 0024 Features O This the 100cc racing kit for SOHC or DOHC with short stroke crankshaft 89mm O This crankshaft is used with SCUT piston 57mm only The crankshaft made by billet forged that specially designed for racing use Die Hard cam chain included 82L Crankshaft is designed for vibrate minimal O To make friction minimal use special bearing Jump Starting and Sudden Acceleration Idling sudden acceleration and sudden engine braking will put a heavy load on the engine which please note may result in crank shaft damage and engine breakage in the worst case The following show the envisioned possibility of injuries to human bodies or property damages as a result of d
7. isregarding the following a Caution cautions O Since this kit is designed and developed for driving in closed races do not use the kit for running on public roads Always try to drive your motorcycle at a legal speed abiding by the laws O Work only when the engine and the muffler are cool Otherwise you will burn yourself Prepare right tools for the work and do the work in the proper and right way Otherwise improper work could cause breakage of parts or injuries to yourself Always use a torque wrench to screw bolts and nuts tight and securely to the specified torque Improper torque could cause these parts to get damaged or fall off 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 Always use new gasket and packing In case you continue using these parts carefully check them for wear or damage and in case wear or damage S is detected always replace those worn or damaged parts with new ones J i Sep 28 11 The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the following cautions Always start the engine in a well ventilated
8. lease take note that the kick starter pinion ype B kick starter pinion 23T 28211 165 T0O type A is unusable ype B kick starter pinion 25T 00 02 0105 f EF Sep 28 11 ie Please do not use with other manufactured products N Others Oil cooler The installation of this Kit increases the heat release value of the engine set off by the increase in engine power For a long time high load riding we recommend you to install an Oil Cooler Kit which keeps oil at appropriate temperatures and prevents such troubles as oil film shortage at high temperatures Thermometer Always use temp gauge to control oil temperature properly Number of revolutions The upper limit of revolutions varies depending on the installed cam shafts cylinder heads etc Please install the tacho meter and be sure not to drive the engine over the limit following the instructions for a cam shaft or cylinder head Take note that idling and sudden acceleration in the 1st and the 2nd gear particularly tend to over reved Over revolutions will result in nonsmooth revolutions of the engine not only adversely affecting the engine life but also breaking the engine in the worst case Kit Contents UU U U U D for 12 V 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
9. lywheel mounting surface If there is a damage replace the flywheel and the crank shaft mn Tapered surface Ur O Check the damage or wear at the connecting rod end 0 Measure the internal diameter at the small end of the con rod lt If larger than 14 05 mm replace it O Measure the clearance at the big end of the con rod in the axial direction If larger than 0 6mm Replace or modify Cylinder edge O Measure the misalignment at two points at the big end of the O Measure the deflection of the crank shaft con rod at right angles to the shaft as shown in the figure on If larger than 0 10 mm Replace or modify the right If larger than 0 05mm replace it 0 Ea Measure the misalignment on the journal bearing of the crank shaft Shaft direction lf larger than 0 10 mm replace it Bearing direction If larger than 0 05 mm replace it Sep 29 11
10. place and do not turn the engine on in an airtight place Otherwise you will suffer from carbon monoxide poisoning When you notice something abnormal with your motorcycle while riding down a road stop riding immediately and park your motorcycle in a safe place Otherwise the abnormality could lead to an accident Before doing work place the motorcycle on level ground to secure it for safety s sake Otherwise your motorcycle could overturn and injure you while you are working O 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 an accident 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 LAs 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 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 Please be informed that we shall be held harmless against any claim against us whatsoever arising out of use of the products in ra
11. r persons who have acquired basic skill and knowledge in tuning We recommend those who are technically inexperienced or without right tools to ask a technically trustworthy specialist shop to do the work The products is installed and being used when you have troubles with the parts during operation we shall be held free and harmless from any and all liabilities or claims for any defects of the parts unless they are genuine parts manufactured by our company TAKEGAWA does not accept returns on any parts which have been modified or installed on a vehicle We do not have any information or service data on the combination of our products and other manufacturers Always use new bolts nuts dowel pins and sealings Never reuse severely worn out or damaged ones Use liquid packing at the specified points only and never use them at unspecified points Otherwise the packing may oppilate oil passages 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 is left in the fuel tank always replace it with high octane gasoline This kit cannot be used for the point ignition system Please be informed that what we can safely say is that the ignition system of this kit is compatible with ours and stock ignition systems because no data is available with us on the compatibility with other ignition syst
12. 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 No Parts Name Oy Repar Parts No Oy B Radial bal bearing 1 ooro T SPECIAL PARTS WNAE YNMA 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 S J ao Sep 28 11 Removal Installation Please do the following work O Attach a cam chain guide sprocket referring to the service and spindle manual O With a special tool fix a crank shaft O Referring to the service manual COMP of the kit into the right demount an engine from the body crankcase O Referring to the service manual Special tool Crank shaft installer disassemble the engine detach a Item No 00 01 1008 stator plate and separate crankcases Caution Do the work with the special tool following the instruction for use of the tool Do not give the crank shaft an excessive Detach an oil pump O Detach a kick starter spindle and then a transmission and gear shift O Apply engine oil to the bearing on J the crankcases Referring to the installation procedures and service manual for your transmission attach the transmission and gear shift drum to the left crankcase i Detach parts on a cam chain tensioner and a guide roller from crankcases
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