Cylinder Kit 178cc(SCUT Cylinder) Instruction manual(For exclusive use in SuperHead+R)
Product number 01-04-0114 (Cylinder Kit)

:KL110A-000001 ～:KL110A-A02833 ～KLX110L:LX110D-A72046 ～KLX110:LX110A-000001 ～:LX110A-A08133 ～Adaptation model
KSR110 (KL110CBF) :JKAKL110CCDA00058 ～KSR110 (KL110DDF) :KL110D-A57002 ～KSR PRO(KL110EEF) :JKAKL110EEDA88121 ～Z125 PRO:BR125H-A02621 ～Requirement
Must equipped with our SuperHead+R
KSR110

COThank you very much for purchasing our products.Thank you so you will comply with the following matters at the time of use.
This is a piston and cylinder kit for exclusive use in SuperHead+R of our make.
Before installation, please check your always kit contents.If there is a point of notice event, Please contact us the dealer of purchase.
◎ If the description, such as photos or Illustration different with this part.

☆ Please read carefully before use ☆

◎ The use ignoring the instructions that are written in the manual, if the accident or damage has occurred, we can not assume any
responsibility for compensation.
◎ This kit is exclusively for SuperHead + R with the above applicable models and chassis numbers. This kit can not be attached toother vehicles or stock cylinder heads.
◎ Work such as engine removal / install is required to install this product. Please prepare genuine service manual for the above-mentioned
applicable models, and work with enough care following instructions in the service manual.In addition, this manual and genuine
service manual are intended for those who have a basic skills and knowledge.If no experience of mounting, etc., who preparation ofsuch a tool is insufficient, we recommend that it is your request to the shop with a technical credit.
◎ This product installation and use, when a problem occurs to after market goods, guarantee other than this product, also can notassume any in any such matters.
◎ If it was the case or mounting that has been processed like a product, it will not be covered under warranty.
◎ It is not possible to inquire of the combination of other manufacturers.
◎ Installation of this kit requires, in some cases, engine removal and crankcase disassembly.Please do the work correctly referring togenuine service manual. And the assembly and installation need gaskets, etc. additionally, which please purchase separately.
◎ Some genuine parts will be reused, but those that are severely worn or damaged. should not be reused and use new ones.
◎ Do not use silicone sealant etc. unless instructed. It can block the oil passages, the worst case can damage the engine.
◎ Be sure to always use premium unleaded petrol. And make sure to check what kind of gasoline is remaining in the fuel tank. Wheneverregular gasoline is left in the fuel tank, always replace it with high-octane gasoline.
◎ Install an oil cooler when necessary.
◎ Engine oil must be API SF or higher class, such as SAE 10W-30 / 20W-50, which are our recommendations.
◎ In case you have purchased this kit for use just as a cylinder kit. Please refer to the attached "Bore Up Kit Reference Table" inthe SuperHead + R instruction manual and collect the dedicated parts.
◎ This kit is only compatible with those engine parts recommended by us. If not listed, use recommended engine parts described in theSuperHead + R instruction manual.

～ feature ～PY○ The cylinder adopts our SCUT design (patented) and made possible a big bore diameter( φ 67mm)which is impossible with theconventional sleeve structure.
○ Ceramic plated alloy integral casting maintains proper piston clearance and reduces friction loss.
○ The piston is designed to be lightweight with maintaining its strength, and the skirt is coated with molybdenum to improve familiarity.

Points to notice about sounds

After installing this product, in some cases a cooling fin in the cylinder may resonate, making a sound. In this case, as a measure,
fix a damper included in the kit to the cooling fin of the cylinder.

About quick starting and sudden acceleration
Please 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.
CautionWhen the handling of ignoring this display, property damage and human shows the assumption of what injury.

■ This product is designed for exclusive use on the closed course.
■ When performing the work, etc., be sure during the cold (when the engine and the muffler is cold). (It may cause burns.)■ When performing the work, it should be made to prepare the tools for the job. (Breakage of parts, it may cause injury.)■ The product and the frame, might have edges or protrusions. Please go to protect your hands when you work. (It may cause injury.)■ Always use new gaskets, packings and the like. Worn or damaged ones may cause accidents because of breakage of these parts.
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)2022.2.2201-04-0114

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Warning

When the handling of ignoring this display people died, shows the contents of the serious injury possibility isassumed.

■ The technology and those who no knowledge, please do not to work.(The cause of parts damage etc., could result in falls and accidents.)■ When performing the work, do the work safely stabilize the vehicle in a horizontal location.
(There is a risk of injury vehicle collapsed while working.)■ Always use new pinston pin circlips, gaskets, packings and the like. Worn or damaged ones may cause accidents because of breakage ofthese parts.
■ If you start the engine, be sure in a well-ventilated place. In the sealed such place, please do not start the engine.
(There is a risk of carbon monoxide poisoning.)■ As gasoline is highly flammable, never place it close to fire. Make sure that nothing flammable is near the gasoline. (It may cause a fire.)■ Do the work must always specified torque using a torque wrench. (Damage of bolts and nuts, and cause of dropout.)■ Never use parts other than those specified by us. (Or, the unspecified parts may break, leading to accidents.)■ When carrying out the inspection and maintenance, etc., if found damaged parts, replace the damaged parts to avoid possible to reuse
the parts. (There is a risk that lead to accidents Continued use.)■ During operation, when an abnormality occurs, immediately stop the vehicle in a safe place, please stop running. (It may lead to an accident.)■ Be sure to each part inspection before operation, check the loosening of the threaded portion, be sure to securely tighten thespecified torque if there is loose. (It may cause detachment of the parts.)■ Inspection, maintenance, the instruction manual or, inspection methods such as service manuals, to protect the way, should be done
correctly. (unsuitable inspection and maintenance, there is a risk that result to an accident.)■ Be sure to always use premium unleaded petrol. (Otherwise, troubles such as knocking of an engine may cause accidents.)

CO◎ Please note. Performance up, the design change, the product and the price in the cost up, etc. are subject to change without 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.
◎ Keep this manual stored until this product is discarded.

※ This kit cannot function on its own.
Applicable camshaft and intake / exhaust parts are
required for Super head + R kit.
（This does not apply to the case where you havepurchased a full kit.）
For more details about the products or queries, please contact
your dealer.
Oil cooler◇ The installaiton of this product increases the heat releasevalue of the engine, set off by the increase in power.
For a long-time high-load running,we recommend you to installan oil cooler kit which keeps oil at appropriate temperaturesand prevents such troubles as oil film shortage at hightemperatures.

Engine oil◇ Engine oil, please use the recommended engine oil.
Recommended:Select a viscosity at ambient temperature and use applications
based on the Honda genuine Ultra G2 or S9 (for 4-cyclemotorcycles) SAE10W-30.
If you use equivalent, should meet these conditions.
・API classification SF, SG or, SG class or higher or equivalent
・JASO standard：MA,MB・SAE standard ：Please use viscosity oil in accordance withoutside air temperature.

PY

Product content

01-13-0109①②④③⑧⑥⑦⑤Number
Product content
1Cylinder, 67mm

Quantity
12Piston, 67mm

1345678

Piston ring set, 67mm
Piston pin, 13x38.5
Piston circlip, 13x1Cylinder head gasket
Cylinder gasket
Damper B

1121129Item Number

13101-KSS-T20R (caution 1)
13101-KSS-T20Y (caution 1)
13101-KSS-T20B (caution 1)
01-15-0104
00-00-1258
00-01-0003 (6 pcs)
00-01-0393
00-01-0392 (2 pcs)
00-01-0342 (10 pcs)

00-00-1211
00-00-1212
00-00-1210(caution 1)Three kinds of pistons are available from these repair parts. As the piston clearance is so little that the cylinder to matchthe limited clearance is required. In ordering the piston, please quote the Item No. in reference to the Inspection manual.
※ Please order in the repair parts are always repair part number. If it is not the part number order, you may not be able to order.
Please be forewarned.
It should be noted, In the case of parts that can not be separately shipment, please order a set part number.
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■ Mounting procedure※ Please refer to the Genuine Service Manual for detailed mounting methods and specified torques that are notspecifically described.

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.
○ Installation of this kit requires, in some cases, engine removal and crankcase disassembly. Please prepare and refer to a genuine
service manual to do the proper installation work.
○ According to the service manual, demount the engine from the frame and and disassemble it.
○ After disassembling the crankcases, check every component referring to the service manual.
Caution: Do inspection of every component and replacement of consumables, with utmost care.

COInspection of Crank Shaft

・Measure the internal diameter at the small end of the con’rod.
∴ If larger than 13.05 mm, replace it.
・Measure the clearance at the big end of the con’rod in the axial
direction.
∴ If larger than 0.4mm, 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 0.07mm, replace it.
YX・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.

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・Measure the deflection of the crank shaft.
∴ 0.08mm or more, need replacement or correction.

7mm

PY

7mm

ｏ Assemble the crankcase referring to the service manual.

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■ Mounting procedure※ Please refer to the Genuine Service Manual for detailed mounting methods and specified torques that are notspecifically described.

Cylinder Installation
Procedures○ Install the damper B in thekit between the cylindercooling fins so that it fits
neatly in the place shown inthe figure.
（This installation is aimed
at reducing a resonant soundfrom a cylinder cooling fin.）○ Apply molybdenum solution tothe piston pin and the holes on
the connecting rod small end.

○ If there is a stamped ← , EX
or IN mark on the top of thepiston, follow the facing
direction.
(IN to the intake, EX to thethe exhaust)then attach to theconnecting rod.

CO

○ Attach the piston pin clip to
one side of the piston.
Attach the piston circlip so
the ring end gap does notmeet with the notch on thepiston pin hole, and it
should be either on the top
or at the bottom of thepiston as illustrated in thefig.

Circlip
ring-end gap○ Air blow the piston ring andpiston pin area and checkthat there is no dust or
foreign matter.
○ Apply engine oil to grooves
for piston rings, and, withreference to the figure below,
fix piston rings and arrange
the location of piston ringend gaps.
Mark side up
Top ring

ExpanderIn the directionof piston pin

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NEW

modify○ Install the cylinder into thestud bolt with compress thepiston ring.

PY

Circlip
ring-end gap○ Remove the cloth used to plugholes.
○ Thoroughly degrease thecylinder base of the crankcase,and fit a dowel pin into thedowel pin hole.
Siderail
Perpendicular tothe piston pin

01-04-0114○ Install the cylinder headfollow to the SuperHead + R
instruction manual.

Caution: Do the work with care
not to damage thepiston rings.

○ Attach the cam chain guidethe cylinder.

Notch in the piston hole

※ When attaching the cam chain
guide to the cylinder, thechain guide may not fit all
the way into the groove due
to individual differences.
Refer to the photo and modify
the chain guide until to getsome play in the lateral
direction, and check that
it is deep enough inside thegroove.

○ Apply engine oil to the insideof the cylinder.

○ Plug the sleeve hole and thecam chain hole on thecrankcase with a clean cloth,and fix a piston pin circlip.
Attach the piston pin circlip
so the ring end gap does notmeet the notch on the piston
pinhole, and ring end gap
should be either on the top orat the bottom of the hole.

Notch in the piston hole

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

B/2toINSPECTION / SERVICE LIMITSWARNING：Since this inspection manual is prepared for those who have acquired basic skills and knowledge intuning, those who are technically unskilled or inexperienced are required not to do the work.
Specification List
Bore diameter
67mm

Stroke length
50.6mm

Displacement
178.3cm3Compression ratio
12.0:1

Reference Value List for Cylinder and Piston Maintenance
Item
Service limit
Remarks
Distortion
0.05mmMore replace
Internal diameter
67.05mmMore replace
PistonExternal diamter（3.5 mm from the hem of a skirt)
66.95mm
Below replace
Internal diameter of a pin hole
13.03mmMore replace
External diameter of a piston pin
12.98mm
Below replace
Piston ring end gap size
TOP0.50mm
More replace
OIL(Side rail)
0.90mmMore replace
Clearance between cylinder and piston
0.05mmMore replace
Clearance between piston and pin
0.05mmMore replace
Cylinder

CO○ Torque unit
1kgf・m = 9.80665 N・m (=newton meter)
MO-OIL ○ This mark shows molybdenum solution.
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.
○ This mark shows those parts to be replaced with every overhaul.
NEWDo not fail to replace these parts every time they are overhauled.

PY・Check the top surface of the cylinder for scratches and damages.
・Check the cylinder top surface for distortion with a straight・Check the inside of cylinder for wear and damage.
edge and thickness gauge.
・Measure the internal diameters of the cylinder bore at 6 positions;∴ Usage Limit：0.05mm or more replaceat the piston pin angle and at the right angle to it (X-Y) eachat upper, middle and lower parts of the cylinder bore.
Straight edge
Treat the largest value as its internal diameter.
∴ If larger than 67.05mm, replace it.
Calculate the clearance between a cylinder and a piston.
Check that the clearance is within the standard value specified
in the specification list.

○ Inspection of Cylinder

INUpperYEXX

MiddleLower

Thickness gauge☆ Cylinder wallPiston part number∴ 66.986 ～ 67.000 → 00-00-1211 (Red paint)∴ 67.001 ～ 67.014 → 00-00-1212 (Yellow paint)∴ 67.015 ～ 67.030 → 00-00-1210 (Blue paint)☆ In case the cylinder wall is beyound the service limits,change the cylinder and piston at the same time as a set.

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○ Inspection of Piston● Supplement

・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.
∴ TOP:If larger than 0.09mm, replace it.

・A number and an alphabet are stamped on the top and side of thecylinder respectively.
In case you cannot measure the cylinder wall, you can designate
the type of the cylinder and order it by the stamped numbers.
∴ This is limited only to the case where there is no damage or
scratch on the cylinder wall.

Piston ring
Push in○ In case you judge by the piston
・After removing the carbon stuck on the piston top, take a note of
the No. stamped on the piston top.
PistonThickness gauge

・Check the piston for damages.
・Measure the external diameter of the piston at the specified placeat the bottom edge of the piston skirt at the right angle to thepiston holes.
∴ If smaller than 66.95mm, replace it.
Figure out the clearance between cylinder and piston.
If not, change the piston with a new one.

CO

13101-KSS-T20*

3.5

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

90°

○ In case you judge by the cylinder

Measurepoint

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

・Take a note of the No. stamped on the side of the cylinder.

PY12101-KSS-T00C
B

Take a note ofthe stamped No.

Piston part number
When an R is stamped → 00-00-1211 (Red paint)
When an Y is stamped → 00-00-1212 (Yellow paint)
When an B is stamped → 00-00-1210 (Blue paint)

・Measure the external diameter of the piston pin.
∴ Piston pin service limit : If it is below 12.98 mm, replace
the piston pin.

○ In case No. is not stamped on the cylinder

・Measure the cylinder by the inspection method described on pageC1, and replace the piston with the one with a specified pistonpart number.

Micrometer

Inportant：Please do the running-in enough.
If you do not do the enough running-in, it might cause toburning piston, or piston will shrink terribly and theknocking sound of piston will bigger.

・Calculate the clearance between the piston and the piston pin.
∴ Clearance 0.05mm or more replace○ Inspection of Piston Ring

〔Ref.〕Running-in
Up to 5000rpm / approx.150km

・Press down a piston ring into the piston with the piston head,and measure the clearance of the ring-end gap at the horizontal
position with a thickness gauge.
∴ TOP:If larger than 0.50mm, replace them.
OIL,Side rail:If larger than 0.90mm, replace it.

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