Instruction Manual for DOHC 4-VALVE HEAD PISTON / CYLINDER KIT

COItem No: ０１−０４−６１９５ (95 cc)
０１−０４−６２１５ (115 cc)
０１―０４―６２２４ (124 cc)

Thank you for purchasing one of our TAKEGAWA’s products.
These piston and cylinder kits are for exclusive use in a motorcycle equipped with a TAKEGAWA’s DOHC 4-valve head. Please strictly follow the following
instructions in installing and using the kit.

Please read the following before starting the installation

о 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 themanual.
о 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 theinstallation and use of the kit.
о If you make modifications to any product of the kit, we shall be held free from any guarantee of the product.
о These products are for exclusive in a motorcycle equipped a TAKAGEWA’s DOHC 4-valve head.
о In case these kits are to be used in a stock crankcase, the crankcase needs to be processed in the section where a sleeve is to be inserted. Consult atechnically-reliable shop specialized in internal combustion products or motorcycles about the processing.
оProcessing of a stock crankcase requires detachment and installation of the engine and separation of the crankcase. Please install the products correctly,
referring to a HONDA’s genuine service manual for the above-mentioned compatible motorcycles. And the assembly and installation require gaskets, etc.,
which please purchase separately.
о These kits are compatible only with motorcycles equipped with a stock or TAKEGAWA-made CDI.

PY

о 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.
The following show the envisioned possibility of injuries to human bodies and property damage as a result of disregarding theCAUTION following cautions.

○These kits are intended for closed course competition purposes only. So, it is prohibited to drive your motorcycle on a public road after the installationof these kits. Drive your motorcycle at a legal speed, abiding by the laws.
○ Make sure before the installation that the engine and muffler are cool. (Otherwise, you will burn yourself.)○ Do the installation with right tools. (Otherwise, breakage of parts or injuries to yourself may take place.)○ As some products and frames have sharp edges or protruding portions, please work with your hands protected. (Otherwise, you will suffer injuries.)
The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding theWARNING following cautions.
○ Those who are technically unskilled or inexperienced are required not to do the work.
(Improper installation because of insufficient skill and knowledge could lead to parts breakage and subsequently to accidents.)○ Always use new piston pin circlips, gaskets and packings. The worn or damaged parts may break the parts, leading 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.)○ If you find damaged parts when checking and performing maintenance of your motorcycle, do not use these parts any longer, and replace them withnew 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 turn on the engine 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 securely up to the specified torque.
(Otherwise, improper tightening may cause parts to come off.)○ When you notice something abnormal with your motorcycle while riding down a road, stop riding immediately and park your motorcyle in a safe place.
(Otherwise, the abnormality could lead to accidents.)○As gasoline is highly flammable, never place it close to fire. Make sure that nothing flammable is near the gasoline. Since vaporized accumulation ofgasoline is at high risk of explosion, work in a well-ventilated place. (Otherwise, it may cause a fire.)○ 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.)○ Never use any other parts than those specified by us. (The use of the unspecified parts may lead to parts breakage and consequent accidents)○ 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.)○ Since vaporized accumulation of gasoline is at high risk of explosion, work in a well-ventilated place. (Otherwise, it may cause an explosion.)○ Fuel must be high-octane gasoline. (Otherwise, troubles such as engine knocking may cause accidents.)◎ 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 racing and the like.
◎ This manual should be retained for future reference.
‑A1‑Aug./23/ 06

〜 Kit Contents 〜
Gasket Kit B
01-13-6001

CO１１０１１６７８９４２５PY３ＡNo.
123456789101113A

Part Name
Aluminum Cylinder
PistonPiston Ring Set (Top, 2nd, Oil)
Piston Pin
Piston Pin Circlips, 13x1
Cylinder Head Gasket
Cylinder Gasket
Rubber Packings (Black)
Rubber Packing (Green)
Dowel Pins, 8x14
Dowel Pins, 8x1295cc / 115cc φ54124cc
φ545495cc / 115cc φ54115cc / 124cc φ54

Qty
111 set12
112
122Repair Part No.

Qty

000-02-102000-02-120

1611212201-13-6001

000-03-123001-01-023
01-01-0251
01-15-015
01-02-6015
01-02-6017∴Please order repair parts by indicating the numbers listed below. In some cases, however,
we may not be able to accept your orders for a single item out of the kit. In this case,please order the required parts in units of a set as shown in the figures below.

‑A2‑Aug./23/ 06

☆ Need boring process to the crancase.

Boring Process to the Crankcase◇ In case you get your crankcase bored outside our factory.

CO○ Joining together the cylinder and the boring-processed section of the crankcase, process the crankcase little by little until the size measures φ 56.8 〜
φ 57.0 mm with a crankcase gasket being squeezed.
※Processing of the crankcase will thin the thinkness of the wall adjoining dowel pin holes. So the durability of the crankcase will be reduced, resulting in thepossible damage of the crankcase in some cases, which please take note.

φ５〜φ ６．
５７ ８．
０２４±０．１２４．５±０．
１

Dowel Pin HolePY
２６±０．１ ２２．５±０．
１GasketDowel Pin Hole２７±０．２Caution○ 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.

3-5-16 Nishikiorihigashi Tondabayashi
Osaka Japan
TEL : 81-721-25-1357
FAX : 81-721-24-5059
URL : http://www.takegawa.co.jp‑A3‑Aug./23/ 06

〜 Installation Procedures 〜
Note: Always use a torque wrench to screw bolts and nuts tight and securely to the specified torque.

Warning : Those who are technically unskilled or inexperienced are required not to do the work.
◇ About the use of inner rotar CDI:

COUsable

Not Usable(Compatible with this kind of base plate)(Not compatible with this kind of base plate)

Only one tap

Tap for 95 cc

Tap for 115cc / 124cc◇ Installation of this kit requires engine removal and crankcase disassembly. Do the work correctly, strictly following a HONDA genuine service manual foryour vehicle.
о Referring to the Honda’s service manual,demount the engine from the frame todisassemble and process the crankcase.

о Make flat the sleeve hole surface by scraping abump, if any, in the sleeve hole of thecrankcase. The bump may push the sleeve.

оAir-blow the piston rings and the piston pin,and check for their jamming any foreignmaterial.

Right crankcase

о Apply engine oil to the piston ring grooves.

о Check every part.
Note : Make sure to check every part and toreplace the consumables correctly.

Items to Be CheckedPY
Left crankcase

Fix the piston rings referring to the figure
below, aligning the rin-end gaps.

GasketAfter scraping
the bump
Sleeve Interferring portion

Cylinderо Connecting rod:・Check the small end for scoring, damages,and discoloration.
・Check the big end for upward and down
ward slack
・Check the surface for damages.
о Oil filterｏ Assemble the crankcase referring to theservice manual.

Top ring

оAttach a piston pin clip to either of the piston pin
grooves.

о Crankshaft
・Misalignment should be within ± 0.03
・Check for damages.
・Check bearings for slack.

１２０°

１２０°

１２０°

Second ring
Expanderо Cam chain push rod:・Check a damper on the head for wear, anddamages.
о Change a damaged part with a new one.
о Completely get rid of the gasket scraps on thecrankcase cylinder base surface with ascraper or a cutter to keep the cylinder baseclear of the dirt.

Side rails

６０°

６０°

о Attach the piston pin circlip so the ring end gap
does not meet with the notch on the piston pinhole, and it should be either on the top or at thebottom of the hole as illustrated in the figure
below.
Top ring
Second ringSide rails

PistonExpanderRing-end gap‑B1‑

Pay attention to the cross section. !

Aug./23/ 06

о Apply engine oil to the piston pin and and to aо Fix a supplied new rubber packing (black) ontohole on the small end of the connecting rod.

the oil-return hole on the cylinder base of thecrankcase.

COоInstall the piston to the connecting rod with theIN mark on the piston facing the intake side.

оApply engine oil to the entire inner surface of thealuminum cylinder bore.

оFit the aluminum cylinder into the stud bolt.

оRemove the waste cloth used to clog the holes.

о Compressing the piston rings, install the cylider

оFix a supplied cylinder gasket into the cylinderand cylinder side bolt for the moment.

о Install the cylinder head with reference to its
instruction manual.

PYоPlug the sleeve hole and the cam chain hole on
the crankcase with a clean cloth, and fix apiston pin circlip.

о Degrease well the cylinder base of thecrankcase, and fix dowel pins onto the dowel
pin holes.

оTemporarily tighten the cam chain guide roller

with care not to get the ring-end gaps out ofalignment.
Note: Be careful not to damage the piston rings.

о Place the cam chain guide roller inside the camchains, as shown in the figure below.

base of the crankcase.

‑B2‑Aug./23/ 06

Benchmark Data for Cylinder and Piston Maintenance
Description
Cylinder

COPistonstock

Distortion
Internal Diameter
External Diameter (1 mm from the lower edge of the skirt)(4 mm from the lower edge of the skirt)
Internal Diameter of Pin HoleExternal Diameter of Piston Pin
Clearance of Piston Ring-End Gap

Clearance between Cylinder and Piston
Clearance between Piston and Pin

φ52
φ54
φ52
φ54

Top
2ndOilService Limit
0.05 mm52.10 mm
54.10 mm
51.96 mm53.97 mm13.03 mm
12.98 mm0.50 mm0.50 mm0.90 mm0.12 mm0.05 mm52.015 〜 52.070 mm
54.015 〜 54.070 mm
51.990 〜 52.000 mm
53.990 〜 54.000 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
0.002 〜 0.014 mm○ Inspection of Cylinder:
・Check the inside of the cylinder for wear and damage.
・Measure and take note of the internal diameters of the cylinder at 6positions: in the direction of piston pins and at the right angle to it (in theX-Y direction) each at upper, middle and lower parts.

INPY

Treat the measured largest value as its internal diameter.
∴ If the diameter is larger than φ 52-52.10 mm and φ 54-54.10 mm,
replace the cylinder.
Figure out the clearance between cylinder and piston.

TopRemarks
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

YEXX

MiddleBottom○ Inspection of Piston:・Clear the piston of the remaining carbon residue.
・Fit a piston ring into the piston, and measure the clearance between
the piston ring and ring groove with a thickness gauge, with a piston
ring being inserted into the ring groove.
∴ If the clearance is larger than 0.17 mm, replace the piston.
・Check the outside of the piston for the damage.

・Measure the external diameter of the piston at the specified place atthe bottom edge of the piston skirt at the right angle to the piston holes.
∴If the diameter is smaller than φ52-51.96 mm and φ54-53.97 mm,replace the piston.
・Measure the internal diameter of the piston pin hole.
∴ If it is larger than 13.03 mm, replace the piston.
・Figure out the clearance between the piston and piston pin.

○Inspection of Piston Ring:
・Insert each piston ring into the cylinder from the bottom.
And measure the clearance of the end gap with a thickness gauge.
∴ If the clerance is larger than 0.5 mm at top and 2nd, or larger than
0.9 mm at oil, change the piston ring.

‑C1‑Aug./23/ 06