R-Stage Cylinder KIT (88cc) Instruction Manual((For R-Stage-equipped motorcycles)
Item No.

Monkey(FI)(AB27-1900001 ～ )Applicable models
Super Cub 50 (AA01-1700001 ～ )and frame No.:
Little Cub(AA01-4000001 ～ )01-04-7003(Cylinder kit)
01-02-7002(Piston kit))Thank you for purchasing one of our 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.
◎ Illustrations and descriptions such as photographs may be different from the present parts, please understand.

About quick starting and sudden acceleration

COPlease note that idling, sudden acceleration, and sudden engine braking will put a heavy load on the engine, and that it may resultin crank shaft and engine damages in the worst case.
☆ Features ☆

○ Cylinder durability, airtightness, and use an all-aluminum cylinder with excellent heat dissipation and minimizes friction loss
subjected to a ceramic composite plated cylinder bore.
○ Oil passage taken out of providing a boss, oil cooler kit can be installed specifications.
○ The expansion of the M5 tap hole in the oil passage plug bolt, can be mounted on our temperature sensor.
○ Soup up to 88cc in bore diameter of 52mm, compression ratio 12.0: 1 high-compression, with improved combustion efficiency.
☆ In order to correctly and safely use ☆

・This product is our R-Stage Cylinder Head kit.It can not be used in this kit alone.
・Prepares the tool or the like at the time of installation, to work with care in accordance with mounting procedure.In addition,
this manual and Honda genuine service manual are intended for those who have a basic skills and knowledge.No attachment experience,
if it is not ready for tools, it is recommended that you ask the high technical credit specialty stores.
・In this installation and use of the product, even if trouble occurs in other parts, do not do parts warranty other than this product.
・Oil cooler kit or, banjo bolt / banjo of oil taken out requires our specialized products.It can not be combined with third party partsand other vehicles supplies.
・When it is machining like the products, do not covered under warranty.
・Please refrain from inquiries about the product and the combination of other companies.
・Be sure to break-in.
・Calorific value due to output up to be installing this kit will also increase.The long-time high-load operation we recommend theinstallation of oil cooler kit.
・To reuse some of the bolts, nuts, pins, packing the heavy wear and damage is to use the new one.
・Please be sure to use the unleaded premium gasoline fuel.We have set such a high compression ratio as compared to genuine, fuel shouldbe always use premium gasoline.The use of regular gasoline, it does not influence the performance of an abnormal combustion, also
piston is broken there is a possibility of causing a serious failure.Please also note the mounting kit before gasoline remaining in
the fuel tank.If regular gasoline remains, be sure replaced with premium gasoline.
・Since this product is a product that was developed for the competition closed course, please do not use public roads.If you want touse public roads, be sure to make a moped registration, please fulfill safety standards of Road Transport Vehicle Act. please try tolaw-abiding operation.
・Please note. If you use in the race, etc., in any case the claim can not be accepted.

CautionPY

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

■ Always try to drive your motorcycle at legal speed, abiding by the laws.
■ Work only when the engine and muffler are cool. (Otherwise, you will get burned.)■ Do the installation with right tools. (Otherwise, breakage of parts or injuries to you 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.)■ Before riding, always check every hardware like screws for slack. If you find slack ones, screw them securely up to the specified
torque.(Otherwise, improper tightening may cause parts to come off.)■ Always use new gaskets and packings. And check those parts, to be reused, for wear and damage. If you find worn or damaged parts,replace them with new ones.

CONTACT Address：3‑5‑16 Nishikiorihigashi Tondabayashi Osaka JAPANTEL: ＋81‑721‑25‑1357 FAX:＋81‑721‑24‑5059 e‑mail:english@takegawa.co.jp URL http:// www.takegawa.co.jp
Please contact with your name and country name provided.（Only English please）
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WarningThe following show the envisioned possibility of human death or serious injuries to human bodies as a result ofdisregarding the 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 malfunction 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.)■ 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 replacethem with new ones. (The continued use of these damaged parts as they are 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 of gasoline is at high risk of explosion, work in a well-ventilated place. (Otherwise it may cause a fire.)CO◎ 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.

01-02-7002①

Product content

01-13-8009⑤⑪②⑨③ ④No.

Part Name

1

Piston (Molybdenum coated)

2345678910111213

Piston ring
Piston pin
Piston pin circlip
Cylinder, 52mm
Oil plug bolt
Oil plug bolt with M5 holes
Sealing washer, 10mm
Cylinder head gasket
Cylinder gasket
Flange bolt, 6x25
Dowel pin, 8x14Mark set⑩⑥⑦⑧PYQty
1
1
12
1
112
111
4
1

Repair Part Item No.
13101-IRS-T00R13101-IRS-T00Y13101-IRS-T00B
13011-181-T1000-01-0091 (With two clips)
00-01-0003 (6 pcs)
12101-GBJ-T02
00-07-0072 (With sealing washer)
00-07-0090 (With sealing washer)
00-07-0010 (10 pcs)
01-13-8009

00-00-0115 (5 pcs)
00-00-0194 (2 pcs)

※ 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 we are not in a position to accept your order injust the quantity to be used. In this case, please take them in the quantity packed.

2015.11.19⑫01-04-7003,01-02-7002

A/2⑬■ Mounting procedure※ With regard to the mounting method and the specified torque of detail, refer to the genuine service manual.

Caution : Always be sure to tighten parts to the specified torque using a torque wrench.
Warning: The unskilled or those without proper knowledge are requested not to do the installation work.
○ Some products involve detachment and installation of an engine
and sepration 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 theframe and disassemble it.
○ You do not have to give boring process to the crankcase.
However, depending on the individual crankcase, there may takeplace interference of crankcase with a cylinder sleeve.
In this case, you are required to modify the crankcase.

CORight-side crankcase

・Measure the misalignment on the journal bearing of the crankshaft.
∴ Shaft direction:If larger than 0.10 mm, replace it.
Bearing direction: If larger than 0.05 mm, replace it.

Left-side crankcase

・Measure the deflection of the crank shaft.
∴ If larger than 0.03 mm, replace it.

GasketAfter modifications

ｏ Check every part.

26mm

Caution: Infallibly inspect every part and check consumable partsfor damage and wear.

What to check:

PYｏ Assemble the crankcase referring to the service manual.

・Measure the internal diameter at the small end of the con’rod.
∴ If larger than 13.10 mm, replace it.
・Measure the clearance at the big end of the con’rod in theaxial direction.
∴ If larger than 0.45 mm, replace it.

・Measure the misalignment at two points at the big end of thecon’rod at right angles to the shaft as shown in the figure on
the right.
∴ If larger than 0.012 mm, replace it.
YX

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30mm

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■シリンダー取り付け要領 ※ With regard to the mounting method and the specified torque of detail, refer to the genuine service manual.
◇ Put the expander.

1.Assemble and install apiston.

◇ Fit a supplied piston pin circlip
securely to the grooves oncirclip.
◇ Attach the piston pin circlip so
the ring end gap does not meet thenotch on the piston pinhole,andring end gap should be either on
the top or at the bottom of thehole.

◇ Fix a supplied piston pin
circlip securely to the grooves
for circlip on one side of thepiston.
Be sure to set a circlip so its
end gap is not on the notch.
◇ Fix the piston pin circlip firston the left side.

◇ Pulling the cam chain, fix theguide roller.
◇ Press in the guide roller so thecenter of the guide roller andthe guide-roller bolt hole on
the cylinder just mesh together.

◇ Put the lower side rail.

◇ Install and tighten a guideroller bolt loosely for now.
◇ Attach the piston pin circlip so
the ring end gap does not meetthe notch on the piston pinhole,and ring end gap should beeither on the top or at thebottom of the hole.
PistonCO

Notch in the piston hole
Circlip ring-end gap◇ Apply engine oil to the piston
ring grooves.
Install the piston rings withthe printed side facing upward,aligning the ring-end gaps.
For details, see the photobelow.

◇ Remove the stuffed waste cloth.

◇ Put the upper side rail.

2.Installation of cylinder.
◇ Degrease the mating surfaces, forholding the gaskets together, on
the cylinder and crankcase.
◇ Install the cylinder gasket.

◇ Fit the second and top rings.

◇ Fit the supplied 8x14 dowel pins.
◇ The boss two places of thesupplied cylinder, attach theoil plug bolt / sealing washer.
Oil plug bolt with M5 holes,
mounted so as to be on the upperside when the engine mounting.
※ If you are installing the oilcooler kit, that you follow theinstruction manual of the kit.

Top ring

120°

PY◇ Apply engine oil to the piston.

120°

120°

MO-OIL

Second ring

ExpanderSidering

60° 60°“IN Mark”◇ Install and tighten a supplied
M6 x 25 flange bolt loosely fornow.

◇ Apply engine oil onto the insideof the supplied cylinder andspread the oil evenly with fingers.

Oil plug bolt with M5 holes
Sealing washer◇ Apply molybdenum solution to thepiston pin on the con’rod.

INMO-OIL

MO-OILThe marking side of thetop ring and the secondring is to be faced up.
※ A ring with a silver-coated side
is a top ring.
Do not make mistakes in choosing
the right rings.
Silver coatedTop ring

◇ Install the piston so the 2 “IN”
mark on the piston head is at theupper side or on the intake side.

INSecond ring

◇ Fit the cylinder by pressing itwith a finger bit by bit, taking
care so the piston ring-end gaps
do not get out of position.

Side ring

PistonExpanderPay attention to the crosssection as well ！！
◇ Air-blow the piston rings andthe piston pin, and check for
jamming of any foreign material
by these parts.
◇ Apply engine oil to the ringgrooves.

2015.11.19◇ Pass the piston pin into con’rod
and piston.

01-04-7003,01-02-7002◇ Once the ring has been placed
inside the cylinder, route the cam
chain through the cylinder, and fix
the cylinder into the crankcase.

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Oil plug bolt

◇ Clean the mating surface of
cylinder and cylinder head, isattached dowel pin, the cylinder
head gasket in the kit to thecylinder.
◇ Attach the cylinder head inaccordance with the instructionsof cylinder head kit.
◇ After cylinder head attached, isattached to cylinder, tighten
the oil plug bolt specified
torque.
Caution: Apply the specified
torque.
Oil plug bolt

Torque：12N・m（1.2kgf・m）

Inspection / Manual
Warning：The cylinder head manual are intended for people who have the basic skills and knowledge. Do not work no person technology and knowledge.

CO○ Inspection of the cylinde・Check the wear and damage to the cylinder inner surface.
・The piston pin direction and its perpendicular axis (X-Ydirection), the upper middle lower, the cylinder bore six
locations were measured and recorded.
Will be inner diameter value is maximum measured value.
∴ Cylinder φ 52.05mm or more exchange・Calculate gap between cylinder and piston to be determined.
∴ Clearance 0.09 or more exchange○ Inspection of the piston
・Remove the dirt of carbon from piston.
・Piston is attached to a piston ring, in a state pushed toring groove, to measure the clearance between piston ring andgroove by feeler gauge.
∴ Topring：0.09mm replace more
2ND ring：0.09mm replace more

○ Inspection of the piston ring・Install piston ring horizontally at the bottom in piston
head, clearance of the end gap is measured by filler gauge.
Topring：0.50mm replace more
2ND ring：0.60mm replace more
Oil side rail：0.90mm replace more

Piston ringShoveINY

TopMidleEX

PistonX

Thickness gauge

・Check the trauma of the piston.
・With respect to the piston pin hole, measure the outside
diameter of the piston at the specified position from thepiston skirt the lower end in the perpendicular direction.

Bottom7.3☆ If the cylinder bore exceeds the allowable limit,
replace the cylinder and piston in the set.
・Inspect scratches and damage to cylinder top.
・Distortion of cylinder top check a straight edge and a
thickness gauge.
∴ Limit of use 0.05mm replace more
Straight

Thickness gauge

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edge

PY
Micrometer90°

The specifiedposition∴ Piston exchanged 51.96mm below
・Calculate gap between cylinder and piston to be determined.
∴ Clearance 0.09 or more exchange
・・Measure the outside diameter of the piston pin.
∴ 12.98 replace below

Micrometer

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PistonringC/1

Important：Please firmly carried out the break-in
operation. Neglect the break-in operation thepiston of the engine seizure or the like oftrouble, or piston there is a possibility that
increases greater shrinkage piston slapping
sound.
[Reference]
Break in 5000rpm or less, about 150 km