R-Stage+D / Instruction Manual for Cylinder Kit

Exclusively for our R-Stage+DCO

Item Nos：０１−０４−７０８８Ｖ（ 88cc）

０１−０４−７０８８ＶＡ （ 88cc）Plated cylinder
０１−０４−７０８８ＶＡＳ （ 88cc）Plated cylinder（106cc）
０１−０４−７１０６Ｖ
０１―０４―７１０６ＶＡ（106cc）Plated cylinder

・Thank you for purchasing one of our TAKEGAWA’s products.
・This is a piston and cylinder set exclusively for R-Stage+D of our own manufacture. In using this set, please strictly observe the following.

Please read the following instructions before installation.

◎ Please note that, in some cases, the illustrations and photos may vary from the actual hardware.
◎ 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 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.
◎ If you make alterations to the products, we shall be held free from any guarantee of the products.
◎ This set is exclusively for R-Stage+D of our TAKEGAWA’s manufacture.
◎ Boring of a crankcase of Item Nos 01-04-7088VA and 01-04-7106VA is required. After reading carefully the attached sheet, please either send thecrankcase to us or consult your local specialist shop handling internal combustion products or motorcycle dealer about the processing.
◎Processing of a stock crankcase requires detachment and installation of the engine and separation of the crankcase. Please install the products correctly,
referring to HONDA’s genuine parts service manual for the the applicable model numbers of the motorcycles. And this assembly requires gaskets, etc.,
which please purchase separately.

PY◎ 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.

CautionThe following show the envisioned possibility of injuries to human bodies or property damages as a result of disregarding thefollowing cautions.

・Since this kit is designed and developed for driving in closed races, do not use the kit for running on public roads.
・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.)
・As some products and frames have sharp-pointed or protruding portions, please work with greatest care. (Otherwise, you will suffer injuries.)

Warning

The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding thefollowing cautions.

・Those who are technically unskilled or inexperienced are required not to do the work.
(Improper installation due to unskilled technique or lack of knowledge could lead to parts breakage and consequently to accidents.)
・Always use new piston pin circlips, gaskets and packing. (Wear and damage to these parts are likely to cause parts breakage and accidents.)
・Before doing work, place the motorcycle on level ground to stablize the position of your motorcycle 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 start it 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 up securely to the specified torque.
(Or improper torque may cause parts to come off, leading to accidents.)
・When you notice something abnormal with your motorcycle while riding down a road, immediately stop riding and park your motorcyle in a safe place.
(Otherwise, the abnormaility could lead to accidents.)
・As gasoline is highly flammable, never place it close to fire. Make sure that nothing flammable is near the gasoline.
(Otherwise, there will be a danger of causing fires.)・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.)
・Never use any other part than the specified parts. (Otherwise, there is a possibility of parts breakage, leading to accidents.)
・Always use a torque wrench to screw bolts and nuts tight and securely to the specified torque.
(Otherwise, improper torque may result in the breakage or coming off of the bolts and nuts, leading to accidents.)
・As the accumulation of vaporized gasoline is at the high risk of explosion, work in a well-ventilated place.
・Always use high-octane gasoline. (Otherwise, troubles such as engine knocking may cause accidents.)◎ Please be informed that the product specifications, design and prices are subject to change without prior notice.
◎ We shall be held free from any guarantee whatsoever of any trouble caused by the combined use of our products with parts not specified by us.
◎ This manual should be retained for future reference.
‑A 1‑

Jun./16/ 08

〜 Kit Contents 〜
１CO

６７

４

８

９

５

１０２

Ａ

６７８No.
12
3
4
56
7
8
910No.
AB

234PY
Ｂ

２88 / 106
88106

52V
52VA （Plated）
52VAS（Plated）
525252Ｃ

３４５ＤParts Name
Qty
Aluminum cylinder
1
Piston1
Piston ring set（top, 2nd, oil） 1
Piston pin 13x36
1
Piston pin circlip
2
Cylinder head gasket
1
Cylinder gasket
1
Rubber packing（black）
2
Dowel pin 8x122
Dowel pin 8x142

Repair Parts Item No.

CD1

３01-13-7003V
01-02-7080
01-02-7060
000-02-120000-03-123
01-01-0222
01-01-022VA（Plated cylinder）
12101-GEF-T20（VAS Plated cylinder）
13101-RSH-T01（for 88cc）
13101-RSH-T01-L（for 106cc）
13011-181-T10
13111-GEF-T01

Parts NameGasket kit , B set
Piston kit
Piston pin circlip set（6 pieces）
Dowel pin set
Aluminum cylinder

PistonPiston ring kit
Piston pin 13X36∴In placing repair parts order with us, please quote the Repair Parts Item Nos.
In some cases, we may not be able to accept your orders for the disassembled components of theabove-mention assembled unit. In this case, please order the components in units of a set component.
‑A 2‑Jun./16/ 08

In case of 01-04-7088VA (88CC plated cylinder) and01-04-7106VA (106cc plated cylinder) cylinder kits

CO

Boring of a Crankcase◇To those who ask other specialist shop than us to do the work
○Joining the cylinders together, process the crankcase little by little until the size isφ56.8〜φ57.0mm with a crankcase gasket placed in between.
※Processing of the crankcase will thin the thinkness of wall adjoining dowell pin holes. So the durabilityof the crankcase will be reduced, resulting in the damage of the crankcase in some cases, which
please take note.

２４．５±０．
１Dowel pin holePY

２６±０．１ ２２．５±０．
１２４±０．１φ５〜φ ６．
５７ ８．
０GasketDowel pin hole２７±０．２

Caution○ Since crankcase boring thins the wall thickness and reduces hardness, becareful in tightening stud bolts.
○Please take note that in some cases the crankcase may get damaged duringuse. Furthermore, please be informed that we shall assume no liability to users
for compensation or damages whatsoever of any kind.

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 3‑

Jun./16/ 08〜 Installation Procedures 〜
Caution: Always be sure to tighten parts to the specified torque using a torque wrench.
Notice: The unskilled or those without proper knowledge are requested not to do the installation work.
○The following show the products of our own make to which this kit cannot be installed.

COusableunusable

one mounting tap

Tap for 88

Tap for 106○Some products involve detachment and installation of an engine andsepration of a crankcase, etc. Do the installation work infallibly, following
Honda’s genuine parts service manual.
○Referring to the service manual, detach the engine from the frame anddisassemble it.
○ The products for Item Nos 01-04-7124V (124cc) ,01-04-7106VA (106ccplated cylinder) and 01-04-7088VA (88cc plated cylinder) entail the boring

Left-side crankcase

ＸPYof the crankcases. Please process the boring of the crankcases referringto the attached sheet.
○ As for the products for Item Nos 01-04-7088V,01-04-7088VAS (88cc)
and 01-04-7106V (106cc), they do not entail the boring of the crankcases.
However, depending on the individual crankcases, the crankcase mayinterfere with the cylinder sleeve in some cases. In such a case, pleasemodify the crankcase.
Right-side crankcase

・Measure the misalignment at two points at the big end of the con’rod atright angles to the shaft as shown in the figure on the right.
∴ If larger than 0.05mm, replace it.
Ｙ・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.

GasketAfter modifications
SleeveCylinderInterference・Measure the deflection of the crank shaft.
∴ If larger than 0.10 mm, replace it.

о Check every part.
Caution: Infallibly inspect every part and check consumable parts fordamage and wear.

What to check:・Measure the internal diameter at the small end of the con’rod.
∴ If larger than 13.03 mm, replace it.
・Measure the clearance at the big end of the con’rod in the axial direction.
∴ If larger than 0.6mm, replace it.

２６ｍｍ

３０ｍｍ

ｏ Assemble the crankcase referring to the service manual.

‑B 1‑

Jun./16/ 08

〜 Cylinder Installation Procedures 〜○ Attach a piston pin circlip to one
of two pin holes on the piston.
NEW○ Apply molybdenum solution to thepiston pin and the holes on theconnecting rod small end.

CO

○ Fix a new rubber packing (black) of
the kit onto the oil-return hole on thecylinder base of the crankcase.

○ Loosely tighten the cam chain
guide roller and the cylinder sidebolt.

MO‑OIL○Attach the piston pin circlip so thering end gap does not meet with
the notch on the piston pin hole,and it should be either on the top
or at the bottom of the piston asillustrated in the fig. 1 below.

End gaps○ Air-blow the piston rings and thepiston pin, and check for jammingof any foreign material by theseparts.

NEW○ Install the piston to the connecting
rod so the EX mark on the piston
faces the exhaust side.

piston rings, and, with reference
to the figure below, fix piston rings
and arrange the location of piston
ring end gaps.

○Loosely tighten an original hex bolt
which holds the crankcase on
the cylinder side.
○ Install the cylinder head withreference to the instruction
manual.

PY○Plug the sleeve hole and the cam
chain hole on the crankcase with aclean cloth, and fix a piston pin
circlip.

○Apply engine oil to grooves for○ Apply engine oil to the entire innersurface of the aluminum cylinder
bore.

○Insert the aluminum cylinder into thestud bolts.

NEW○Remove the cloth used to plug holes.

○ Degrease the cylinder base of thecrankcase, and fix 8x12 dowel pins
onto the dowel pin holes.
Top ring (gray)
１２０°○ Compressing the piston rings,
install the cylinder with care not tomove the piston-ring end gaps outof place. Their end gaps will not be
out of place.
CAUTION: Be careful not to damage
the piston rings.

１２０°

１２０°

Second ring (black)
ExpanderSide rails○ Fix a cylinder gasket of the kit into
the cylinder base of the crankcase.

６０° ６０°○ Place the cam chain guide roller on
the cam chains.

NEWTop ring
Second ringSide rails

PistonExpanderPay attention to the crosssection as well！！
‑B 2‑

Jun./16/ 08

Bore stroke
87.9 cm

Displacement

Specification List52 x 41.4
106.1 cm 3352 x 50

Compression ratio
13.4 : 1

13.3 : 1

Owner’s Manual
WARNING52.015〜52.070 mm
52.000〜52.015 mm
51.980〜52.000 mm
13.002〜13.008 mm
12.994〜13.000 mm
0.15〜0.38 mm
0.20〜0.45 mm
0.20〜0.70 mm

Stock

Specification List for Cylinder & Piston
Item

φ52
φ52 Plated
φ52

Top
2ndOil
φ52
φ52 Plated

0.002〜0.014 mm

Remarks
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace‑C 1‑

Since this cylinder manual is prepared for those who have acquired basic skills and knowledge in tuning, those who are technically unskilled or inexperienced are required
not to do the work.

Item No.
01-04-7088V
01-04-7088VA
01-04-7088VAS
01-04-7106V
01-04-7106VA

Cylinder Distortion
Internal diameter
PistonExternal diamter（6 mm from the hem of a skirt)
Internal diameter of a pin hole
External diameter of a piston pin
Piston ring end gap size

Clearance between cylinder and piston

Clearance between piston and pin○Torque unit
1 kgf・m = 9.80665 N・m (=newton meter)○This mark shows molybdenum solution.

○This mark shows those parts to be replaced with every overhaul.
Do not fail to replace these parts every time they are overhauled.

MO‑OILNEW○ Engine oil → mark∴Apply engine oil where so indicated.

OIL

This solution is a mixture of molybdenum grease and engine oil (in the ratio of 1:1).
∴Apply molybdenum solution or assembly paste to the portions where it is indicated that molybdenum solution needs to be applied.

Service limit
0.05 mm52.10 mm52.05 mm
51.96 mm13.03 mm
12.98 mm0.50 mm0.50 mm0.90 mm0.12 mm0.03 mm0.05 mm

PYCO● Inspection of Cylinder
・Check the inside of cylinder for wear and damage.
・Measure the internal diameters of the cylinder boreat 6 positions; at the piston pin angle and at the rightangle to it (X-Y) each at upper, middle and lower parts∴ If larger than 52.10mm at φ 52, replace it.

of the cylinder bore.
Treat the largest value as its internal diameter.

ＹＥＸ

If larger than 54.10mm at φ52, replace it.
Calculate the clearance between a cylinder and apiston.

ＩＮ
上中下‑C 2‑

Ｘ

Owner’s Manual・Check the top surface of the cylinder for scratches
and damages.
・Check the cylinder top surface for distortion with astraight edge and thickness gauge.
∴Service limit:If the distortion is more than 0.05 mm,replace the cylinder.

● Inspection of Piston

・Clear the piston of the remaining carbon residue.
・Fit a piston ring into the piston, and measure theclearance between the piston ring and ring groove
with a thickness gauge.
∴If larger than 0.17mm, replace it.

・Check the piston for damages.
・Measure the external diameter of the piston at thespecified place at the bottom edge of the piston skirt
at the right angle to the piston holes.
∴ If smaller than 51.96mm at φ 52, replace it.

PYCO

・Measure the internal diameter of the piston pin hole.
∴If larger than 13.03mm, replace it.

・Measure the external diameter of the piston pin.
replace the piston pin.

∴Piston pin service limit : If it is below 12.98 mm,

Owner’s Manual● Inspection of Piston Ring
・Press down a piston ring into the piston with thepiston head, and measure the clearance of thering-end gap at the horizontal position with athickness gauge.
∴Top and 2nd : If larger than 0.5mm, replace them.
Oil: If larger than 0.9mm, replace it.

PYpiston pin.

・Calculate the clearance between the piston and theCO●Supplement:

・If you intend to change the piston with a new one, you

can order the one from us by the number stamped on

the top of the piston.

・After removing the carbon stuck on the piston top,
take a note of the No. stamped on the piston top.

Example:13101-RSH-T01

・Order the piston by the No. stamped on the piston top.

‑C 3‑