Instruction Manual for Cylinder Set (124 cc)

COExclusively for our Twin Spark Super Head +R
Item Nos：０１−０４−８２２４（124cc）

・Thank you for purchasing one of our TAKEGAWA's products.
・These Piston and Cylinder kits are for exclusive use in motorcycles equipped with our TAKEGAWA-made Twin Spark Super Head+R. In using these kits,please strictly observe the following.

Please read the following instructions before installation.

◎ 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 inthe manual.
◎ We shall be held free from any responsibility or compensation whatsoever for any glitch in parts other than ours if the glitch takes place after theinstallation and use of this product.
◎ If you make alterations to the products, we shall be held free from any guarantee of the products.
◎ These Piston and Cylinder kits are for exclusive use in motorcycles equipped with our TAKEGAWA-made Twin Spark Super Head+R.
◎ In case this set is to be used in a stock crankcase, the crankcase needs to be processed in the section where a sleeve is attached. Please contact yourspecialist shop handling internal conbustion products or a motorcycle shop nearby.
◎ Processing of a stock crankcase requires detachment and installation of the engine and separation of the crank case. 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

PY

gaskets, etc., which please purchase separately.
◎ This set is for exclusive use in CDI motorcycle, but is compatible only with a stock CDI and CDI of our own make.
◎ 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 ofknowledge 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 dangerof causing fires.)・Check or perform maintenance of parts correctly according to the procedures in the instruction manual or a service manual. (Improper checking ormaintenance 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 thebreakage 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.
‑A1‑Sep./12/ 06

〜 Kit Contents 〜
１６

７CO

４

８

５

１０

２

７

８

９No.
１２
３
４
５
６
７
８
９１０
１１

１１

３

Ａ

６９PYＢ

２

４

３

５Parts Name
Aluminum cylinder
PistonPiston ring set（top, 2nd, oil）
Piston pin
Piston pin circlips
Cylinder head gasket
Cylinder gasket
Rubber packing（black）
Rubber packing（green）
Dowel pins 8x12
Dowel pins 8x14ＣＤQty
１１１１２１１２１２２Repair Parts Item No.
No.
Parts Name
Ａ０１―１３―８００３
Gasket kit
Ｂ １２４ ０１―０２―８２４１
Piston kit
Ｃ０００―０２―１２０
Piston pin circlip set（6 pieces）
Ｄ
０００―０３―０５１
Dowel pin set
１
５４ ０１―０１―０２５１
Aluminum cylinder
２
５４ １３１０５―２ＳＭ―Ｔ０１―ＬＴ（for 124cc） Piston３
５４ ０１―１５―０１５Piston ring kit
４０００―０２―１０２
Piston pin∴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 componentsof the above-mention assembled unit. In this case, please order the components in units of aset component.
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Sep./12/ 06

01-04-8224 (124cc) cylinder kits
Boring of a Crankcase

CO◇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 is φ 56.8 〜φ 57.0 mm with a crankcase gasket placed in between.
※ Processing of the crankcase will thin the thinkness of wall adjoining dowell pin holes. So the durability of the crankcase will be reduced, resulting in thedamage of the crankcase in some cases, which please take note.

２４．５±０．
１

Dowel pin holePY

２６±０．１ ２２．５±０．
１２４±０．１

φ５〜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.

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

Sep./12/ 06

〜 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.
◇ On the use of an old-type inner rotar CDI

COusableunusable

one mounting tap

Tap for 88

Tap for 106

・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.

○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 installation of this kit entails boring process to a crankcase.
Please proces the boring of the crankcase referring to the attached sheet.

Right-side crankcase

Left-side crankcase

GasketＹ

PY
Ｘ

After modifications

SleeveCylinderInterference・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.

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

What to check:・Measure the deflection of the crank shaft.
∴ If larger than 0.10 mm, replace it.

・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.

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Sep./12/ 06

〜 Cylinder Installation Procedures 〜○ Attach a piston pin circlip to oneof 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 as
illustrated 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 IN mark on the piston faces
the intake side.

which holds the crankcase on
the cylinder side.

PY○Insert the aluminum cylinder into thestud bolts.

NEWring end gaps.

○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
１２０°

１２０°

１２０°

○Loosely tighten an original hex bolt

○ Install the cylinder head withreference to the instruction
manual.

○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 forpiston rings, and, with reference
to the figure below, fix piston rings
and arrange the location of piston○ Apply engine oil to the entire innersurface of the aluminum cylinder
bore.

○ Compressing the piston rings,
install the cylinder with care not tomove the piston-ring end gaps outof place. Their end gaps will not beout of place.
CAUTION: Be careful not to damage
the piston rings.

Second ring
ExpanderSide rails

６０° ６０°○ Fix a cylinder gasket of the kit into
the cylinder base of the crankcase.

IN○ Place the cam chain guide roller on
the cam chains.

NEWTop ring
Second ringSide rails

PistonExpanderPay attention to the crosssection as well！！
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Sep./12/ 06

Reference Value List for Cylinder and Piston Maintenance
ItemStock

Cylinder Distortion
Internal diameter

COPiston

External diamter（1 mm from the hem of a skirt)（7 mm from the hem of a skirt)
Internal diameter of a pin hole
External diameter of a piston pin
Piston ring end gap size

φ52φ54
φ52
φ54Top2ndOilClearance between cylinder and piston
Clearance between piston and pin

Service 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
51.980〜52.000 mm
53.980〜54.000 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 cylinder for wear and damage.
・Measure the internal diameters of the cylinder bore at 6 positions; at thepiston pin angle and at the right angle to it (X-Y) each at upper, middle andlower parts of the cylinder bore.
Treat the largest value as its internal diameter.

IntakeUpper

Y

Remarks
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

ExhaustX

PY∴ If larger than 52.10mm at φ 52, replace it.
If larger than 54.10mm at φ 52, replace it.
Calculate the clearance between a cylinder and a piston.

MiddleLower○ Inspection of Piston
・Clear the piston of the remaining carbon residue.
・Fit a piston ring into the piston, and measure the clearance between thepiston 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 the specified place at thebottom edge of the piston skirt at the right angle to the piston holes.
∴ If smaller than 51.96mm at φ 52, replace it.
If smaller than 53.97mm at φ 54, replace it.
・Measure the internal diameter of the piston pin hole.
∴ If larger than 13.03mm, replace it.
・Calculate the clearance between the piston and the piston pin.

○ Inspection of Piston Ring
・Press down a piston ring into the piston with the piston head, andmeasure the clearance of the ring-end gap at the horizontal position witha thickness gauge.
∴Top and 2nd : If larger than 0.5mm, replace them.
Oil: If larger than 0.9mm, replace it.

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Sep./12/ 06