Upload
others
View
4
Download
0
Embed Size (px)
Citation preview
COPY
-1- Feb./22/â06
ăťThank you for purchasing one of our TAKEGAWA's products. Please strictly follow the following instructions in installing and using the products.ăťBefore fitting the products, please be sure to check the contents of the kit. Should you have any questions about the products, please kindly contact yourădealer.
Please read the following before starting the installationâ We do not take any responsibility for any accident or damage whatsoever arising from the use of the products not in conformity with the instructions inăthe manual.âThis kit is designed for exclusive use in the above-mentioned applicable models of motorcycles and frame numbers only. Please take note that this kit ăăcannot be mounted on other types of motorcycles.â Installation of this product requires removal and installation of an engine, and disassembly of a crankcase. Please prepare HONDAâs service manual forăan above-mentioned applicable vehicle, and work with enough care following the instructions in the service manual. Besides, this instruction manual, asăwell as HONDAâs service manual, is prepared for persons who have acquired basic skill and knowledge in tuning. We recommend those who are ăăătechnically inexperienced or without right tools to ask a technically-trustworthy specialist shop to do the work.â 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 thanăthis one after the installation and use of this product.â If you make alterations to the products, we shall be held free from any guarantee of the products.â You are kindly requested not to contact us about the combination of our products with other manufacturersâ.ăâ Always use new bolts, nuts, dowel pins and packings. Never reuse severely worn-out or damaged ones.âUse liquid packings at the specified points only, and never use them at unspecified points. Otherwise, the packings may oppilate oil passages; it may breakăthe engine in the worst case.âBe sure to always use premium unleaded petrol. And make sure to check what kind of gasoline is remaining in the fuel tank. Whenever regular gasolineăis left in the fuel tank, always replace it with high-octane gasoline.â Never use this kit on the point-ignition system motorcycle.âPlease 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 dataăis available with us on the compatibility with other ignition systems. Therefore, please never use other ignition systems, which may cause technical ăăătroubles.â Install an oil filter outside.â Install an oil cooler whenever necessary.â Engine oil must be API SF or higher class, such as SAE 10W-40 / 15W-50, which are our recommendations.â The upper limit of the engine revolutions is 12,000 rpm. Please install a tachometer to ensure that you drive at revolutions below 12,000 rpm.â Change the sprocket with the one which meets the output and specifications.â This kit cannot perform on its own.â 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 ourărecommendations.â The installation of this kit entails crankcase boring process. For the details, please refer to the attached sheet.
ď˝ Features ď˝â The combined use of this kit with the bore-up kit of our own make will have a remarkable effect, increasing the engine displacement to 124 cc.â The crank shaft is made light in weight via the introduction of the balance cut aimed at reducing waggling.
â Please be informed that, mainly because of improvement in performance, design changes, and cost increase, the product specifications and pricesăare subject to change without prior notice.â 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.â This manual should be retained for future reference.
Idling, sudden acceleration, and sudden engine braking will put a heavy load on the engine, which please note may result in crank shaft damage andengine breakage in the worst case.
Jump-Starting and Sudden Acceleration
Item No.ďźďźâďźďźâďźďźďźďź
Monkey ďźZ50J-2000001ď˝ XR50R ďźAE03-1000001ď˝Gorilla ďźZ50J-2500001ď˝ CRF50F ďźAE03-1400001ď˝Monkey BAJA ďźZ50J-1700001ď˝ XR70RăăďźDE02-1000001ď˝Monkey R ďźAB22-1000017ď˝ CRF70F ďźDE02-1700001ď˝Monkey RT ďźAB22-1007601ď˝
Applicable Models and Frame Nos6V Monkey / Gorilla L crank: Z50J-1600008ď˝1805927
ďźďźâďźďźâďźďźďźďź
ăťSince 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 youră motorcycle at a legal speed, abiding by the laws. ăťWork only when the engine and the muffler are cool. (Otherwise, you will burn yourself.) ăťPrepare right tools for the work, and do the work in the proper and right way.(Otherwise, improper work could cause breakage of parts or injuriesă to yourself.) ăťAlways use a torque wrench to screw bolts and nuts tight and securely to the specified torque. (Improper torque could cause these parts to getă damaged or fall off.) ăťAs some products and frames have sharp edges or protruding portions, please work with your hands protected. (Otherwise, you will suffer ă ăă injuries.) ăťBefore riding, always check every section for slack in parts like screws. If you find slack ones, screw them securely up to the specified torque. ăă (Or improper torque may cause parts to come off.) ăťAlways use new gasket and packing. In case you continue using these parts, carefully check them for wear or damage, and in case wear or ăă damage is detected, always replace those worn or damaged parts with new ones.
The following show the envisioned possibility of injuries to human bodies or property damages as a result of disregarding the followingcautions.Caution
â Please note that, in some cases, the illustrations and photos may vary from the actual hardware.
Instruction Manual for Stroke-Up Crank KitStroke: 54 mm
COPY
-2- Feb./22/â06
âCautions before ridingâ On fuel to useăăWhenever regular gasoline is remaining in the fuel tank, always replace it with high-octane gasoline.
âťThis kit is compatible with the engine parts of our recommendations only. Therefore, please replace the engine parts not recommendated by us with thoseăof our recommendations.
âEngine parts of our recommendation
⥠On sprocket change â The installation of this kit will increase the power of your vehicle. So use of a stock sprocket will result in severe wears of parts because of the too lowăăgear, not only adversely affecting the engine life, but also breaking the engine in the worst case. Please get your sprocket high-geared.
â On the use of old-type inner rotar C.D.I.
âOur products that cannot be used:
â About the case of using 5-speed transmission
ăâIn case you install a 5-speed transmission kit ăăăand your kick starter spindle is type A, make ăăăsure to change the spindle to type B spindle. ăăăThis will improve the efficiency in transmittingăăthe torque at the time of kick start and reduce ăăăthe load on the gear which will lead to theăăprevention of gear breakage.
ăâ It is necessary to change a kick starter pinionăăas well at the time of changing the kick-starterăăspindle type B. Change it with the right one withăăthe number of teeth to match the transmissionăăkit. Please take note that the kick starter pinionăătype A is unusable.
The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding thefollowing cautions.
ăťAlways start the engine in a well-ventilated place, and do not turn the engine on in an airtight place. (Otherwise, you will suffer from carbon ăăăă monoxide poisoning.) ăťWhen you notice something abnormal with your motorcycle while riding down a road, stop riding immediately and park your motorcyle in a safe ăă place. (Otherwise, the abnormaility could lead to an accident.) ăťBefore doing work, place the motorcycle on level ground to secure it for safety's sake. (Otherwise, your motorcycle could overturn and injure youă while you are working.) ăťCheck or perform maintenance of parts correctly according to the procedures in the instruction manual or a service manual. (Improper checking oră maintenance could lead to an accident.) ăťIf you find damaged parts when checking and performing maintenance of your motorcycle, do not use these parts any longer, and replace them ăă with new ones. The continued use of these damaged parts as they are could lead to an accident.) ăťAs gasoline is highly flammable, never place it close to fire. Make sure that nothing flammable is near the gasoline. Since vaporized accumulation ofă gasoline is at high risk of explosion, work in a well-ventilated place.
Warning
ďźďźâďźďźâďźďźďźďź
Bore-up kit DOHC bore-up kitSuper head bore-up kitSuper head+R bore-up kitR Stage+D bore-up kit Regular head bore-up kit
Clutch Dry-type clutch kit Special clutch kit
Ignition system Stock C.D.I.Hyper C.D.I.C.D.I. magnet kit: 005-02-051
Recommended parts
Usable
Not usable
Tap for 88
Tap for 106
Only one tap forinstallation Please never use an old-type unusable base plate,
because the use of it as it is is at high risk of caus-ing troubles. So, change it with the one of our rec-ommendations.
Type B
Kick starter pinion
Kick starter pinion
Type A
Parts Name Item No.Type-B kick starter spindle kit 002-04-001 Type-B kick starter pinion 23T K-23B Type-B kick starter pinion 25T K-25B
ďźďźâďźďźâďźďźďźďź
Bore-up kit DOHC bore-up kitSuper head bore-up kitSuper head+R bore-up kitR Stage+D bore-up kitRegular head bore-up kit
Clutch Dry-type clutch kitSpecial clutch kit
Ignition system C.D.I.magnet kit:005-02-082C.D.I.magnet kit:005-02-031
Recommended parts
COPY
-3- Feb./22/â06
ď˝ Kit Contents ď˝
âOthersâ Oil cooler:âThe installation of this product increases the heat release value of the engine, set off by the increase in power. For a long-time and high load running, weărecommend you to install an oil cooler kit which keeps oil at appropriate temperatures and prevents such troubles as oil film shortage at high temperatures.
â The ignition systems with faster ignition timing than our settings are excluded. So please never use ignitionăsystems in combination with other manufacturersâ, which may cause technical troubles.
ďź
ďźďźâďźďźâďźďź(for 6 V)ďźďźâďźďźâďźďź(for 12 V)
ďź
ďź
ďź


ďźďźâďźďźâďźďźďźďź (for 12 V)
â´Please order repair parts by indicating the Repair Parts No. listed below. As for the assembled sets, in some cases, we may notăbe able to accept your orders for the disassembled components of the above-mention assembled unit. In this case, please orderăthem in units of sets instead of the disassembled component parts.
ďź
ďź
ďź
ďź
ďźďźďźâďźďźâďźďźďź
ďź
ďź
ďźďźâďźďźâďźďźďźďź (for 6 V)
âNumber of revolutionsâThe upper limt of revolutions varies depending on the installed cam shafts, cylinder heads, etc. Please install a revolution counter to make sure that youădrive the engine at revolutions below the upper limit, following the instructions for a cam shaft or cylinder head.âTake note that idling and sudden acceleration in the 1st and the 2nd gear particularly tend to exceed the the upper limit. Over revolutions will result in ăănonsmooth revolutions of the engine, not only adversely affecting the engine life, but also breaking the engine in the worst case.
âĄThermometer: It is advisable to use a thermometer to control the oil temperatures. (007-04-0013)
Symbol Parts Name Qty Repair Parts No. Qty Radial ball bearing ďź TMB304JR2 / 22CS14 ďźďź˘ Timing sprocket ďź 14311-035-T00 ďź
N0. Parts Name Qty Repair Parts No. Qtyďź Crank shaft ďźďź°. ďź 01-10-0081 ďźďź Woodruff key ďź 000-10-0006 ďźďź Crank case gasket ďź 000-13-032 ďźďź Right-side crank case gasket ďź 11394-035-T00 ďźďź Stud bolt A (long) ďź ďźďź Stud bolt B (short) ďź ďźďź Heavy-duty cam chain (84L) ďź 01-14-003 ďźďź Cam chain guide spindle ďź 14675-035-T00 ďź
000-03-049
No. Parts Name Qty Repair Parts No. Qtyďź Crank shaft COMP. ďź 01-10-0091 ďźďź Woodruff key ďź 000-10-0007 ďźďź Crank case gasket ďź 1191-GB4-T00 ďźďź Right-side crank case gasket ďź 11394-035-T00 ďźďź Stud bolt (A) (long) ďź ďźďź Stud bolt (B) (short) ďź ďźďź Heavy-duty cam chain (84L) ďź 01-14-003 ďź
000-03-049
COPY
-4- Feb./22/â06
Boring of a Crankcase
âTo those who ask other specialist shop than us to do the work
âJoining the cylinders together, process the crankcase little by little until the size isĎ56.8ď˝Ď57.0 ăămm with a crankcase gasket placed in between.âťProcessing of the crankcase will thin the thinkness of wall adjoining dowell pin holes. So the durabilityăof the crankcase will be reduced, resulting in the damage of the crankcase in some cases, which ăăplease take note.
Gasket Dowel pin holeďźďźÂąďźďźďź
Dowel pin hole
ďźďźÂąďźďźďź
ďźďź
Âąďźďźďź
ďźďźďźďź
Âąďź
ďźďź
ďźďźďźďźÂąďźďźďź
Ďďźďźďź
ďź
ăď˝Ďďź
ďźďźďź
â Since crankcase boring thins the wall thickness and reduces hardness, be ăăcareful in tightening stud bolts. ăâPlease take note that in some cases the crankcase may get damaged during ăăuse. Furthermore, please be informed that we shall assume no liability to usersăfor compensation or damages whatsoever of any kind.
Caution
ă3-5-16 Nishikiorihigashi Tondabayashi Osaka JapanTEL : 81-721-25-1357ăFAX : 81-721-24-5059URL : http://www.takegawa.co.jp
Co.,Ltd.
COPY
-1- Feb./22/â06
ď˝ Installation Procedures ď˝Removal
â Referring to the service manual,ădismount the engine from the ăăframe.
â´ Do the following workăreferring to the relative serviceămanual.
â Referring to the service manual,ădisassemble the engine, detach ăăthe stator plate, and thenădisassemble the crankcase.
âRemove the oil pump.
âAfter removing the kick starter ăăspindle, remove the transmissionăand the gear shift drum as they ăăare.
â Remove the crank shaft.
âRemove each part on the cam ăăchain tensioner and the guide ăăroller from the crankcase.
âRemove the stud bolt from the ăăcrankcase.
â Enlarge the orifice diameter on theăright-side crankcase referring to theăinstruction manual for Super Oil ăăPump.
Installation
âInstall the cam chain guide sprocketăand the spindle.
â Apply engine oil to the bearings inăthe crankcase.
âInstall the transmission and the gearăshift drum to the left-side crankcaseăwith reference to the instruction ăămanual and the service manual forăthe transmission.
â Install the starter spindle.
âApply engine oil to the big end of theăcrank shaft and the bearings.
â Attach the crank shaft onto the ăăcrankcase, and fix dowel pins intoăthe crankcase.
â Attach kitâs gasket to theăcrankcase, and install the right sideăcrankcase.
âAfter applying a little AlumiăSpecial to the threaded portion ofăthe crankcase bolts, install the ăăbolts onto the crankcase and ăătighten them diagonally to the ăăspecified torque.ăCAUTION: Be sure to tighten to theăăăăăăspecified torque.ăT=10Năťm (1.0kgfăťm)
â Being careful of the direction ofăthe gear shift drum washer, ă ă
ătighten it to the specified torqueăwith a hex bolt, and attach aărubber plug. CAUTION: Be sure to tighten to ăăăăăăăthe specified torque.ăT=12Năťm (1.2kgfăťm)
â Get the boring process done.ăGet the boring process done to theăcrankcase, referring to the attachedăsheet.
â´6V vehicleâ In the case of a 6V vehicle, changeăspindles from a cam chain spindle toăa spindle of the kit, and install it.
Guide sprocket
8 Change to a cam chain spindle of the kit.
â Clean the crankcase.
COPY
-2- Feb./22/â06
â Install the parts on theătransmission with reference to theăinstruction manual and the serviceămanual for the transmission.
â Flatten the surface by cutting offăthe hole section of the crankcaseăgasket and the mating surface ofăthe cylinder.âť Be careful not to get any gasketăchips in the crankcase.
âFix the oil filter screen, and installăSuper Oil Pump referring to the ăăinstruction manual.
â Install a clutch with reference toăthe instruction manual for theărelative clutch kit.
â Fit a kitâs cam chain in the crank ăăshaft, and install the tensioner roller.
â Attach O-rings to the two spots.
âFix a generator plate, and tighten theăflat screws.
âFix the woodruff key to the crank ăăshaft.
â Install the cylinder, following theăcylinder installation procedures.
â Degrease the tapers on theăflywheel of the crank shaft, andăinstall the flywheel. After applyingăscrew locking agent a little to the ăăwashers and flange nuts, tighten ăăthem to the specified torque.ăCAUTION: Be sure to tighten to theăăăăăăspecified torque.ăT=44Năťm (4.5kgfăťm)
â Specialized Tools
â Conârod stopperăItem No.: 000-01-01
â Lock nut wrenchăItem No.: 000-01-021 for 12.7 mmăăăăăăăăăăăăă(1/2)ăItem No. : 000-01-022 for 19.5 mmăăăăăăăăăăăăă(3/8)
â Flywheel pullerăItem No.: 000-01-031
â Universal holderăItem No.: 000-01-1002
â After applying Alumi Special a littleăto the threaded part of the stud bolts,ăattach stud bolts to the crankcase,ăand tighten them to the specified ăătorque. Fix the stud bolt B, the shorterăstud bolt, to the clutch side.ăT=10Năťm (1.0kgfăťm)
â In case you use a magnet kit ăăothern than a stock magnet kit,ăfix the magnet following theăinstallation procedures of the ăămagnet kit.
COPY
Feb./22/â06
ďźďźď˝ď˝ ďźďźď˝ď˝
ďźš

Reference Value List for Crank Shaft Maintenance
Items Stock Service limit NotesInternal diameter of con'rod at small end 13.003ď˝13.012mm 13.03mm ReplaceClearance between con'rod's small end and a pin 0.003ď˝0.018mm 0.035mm ReplaceMisalignment on con'rod's big endă(longitudinal and transversal direction) 0ď˝0.012mm 0.05mm ReplaceăăăăăăăăăăăăSide clearance 0.1ď˝0.35mm 0.6mm ReplaceFree play on the journal bearings (in the direction of shaft) 0.1mm Replaceăăăăăăăăăăăăăă (in the direction of bearings) 0.05mm ReplaceCrank shaft deflection 0.03mm 0.1mm Replace
â Inspection of Crank ShaftăăťCheck the crank shaft for damages on the flywheel-mounting surface.ăăIf there is a damage, replace the flywheel and the crank shaft.
ăăťMeasure the internal diameter at the small end of the conârod.ăăâ´ If larger than 13.03 mm, replace it.ăăťMeasure the clearance at the big end of the conârod in the axial direction.ăăâ´ If larger than 0.6mm, replace it.
Tapered surface
ăăťMeasure the misalignment at two points at the big end of the conârod at ăăăright angles to the shaft as shown in the figure on the right.ăăâ´ If larger than 0.05mm, replace it.
ăăťMeasure the misalignment on the journal bearing of the crank shaft.ăăâ´ Shaft direction:If larger than 0.10 mm, replace it.ăăăBearing direction: If larger than 0.05 mm, replace it.
ăăťMeasure the deflection of the crank shaft.ăăâ´ If larger than 0.10 mm, replace it.