Cylinder Kit 138cc (Plated cylinder) Instruction manual(For exclusive use in SuperHead+R)
Product number

01-04-0105 (Cylinder Kit)
01-02-0102 (Piston 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
KSR110Thank 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.

CO◎ 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.
◎ The cylinder sleeve of this product may interfere due to individual differences in the stock crankcase. If there is interference,the crankcase needs processing.
◎ Processing of stock crankcases requires detachment and reinstallation of an engine and separation of crankcases. Please do the work
correctly referring to genuine service manual. And the assembly and installation need gaskets, etc. additionally, which pleasepurchase 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 is made of alloy integrally cast sleeve with ceramic plating to improve durability / wear resistance compared to castiron sleeve, maintain proper piston clearance, and reduce friction loss.
○ The piston is lightweight and the skirt is coated with molybdenum to improve adaptation.

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)2022.2.22

01-04-0105,01-02-0102

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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 arerequired 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

01-02-0102 Piston Kit①②01-13-054③⑦⑥④⑧⑤Number
Product content
1Cylinder, 59mm
2Piston, 59mm
3Piston ring set, 59mm
4Piston pin, 13x365Piston circlip, 13x1
6Cylinder head gasket
7Cylinder gasket
8Damper B
2022.2.22

Quantity
Item Number
101-01-0102
113110-KSH-T02
101-15-023※ Please order in the repair parts are always repair
part number.
100-01-0091 (with circlip)
If it is not the part number order, you may not be
200-01-0003 (6 pcs)
able to order.Please be forewarned.
100-00-1152
It should be noted, In the case of parts that can not
100-00-1125
be separately shipment, please order a set part
1900-01-0342 (10 pcs)
number.
01-04-0105,01-02-0102

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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.
○ A crankcase may interfere with a cylinder sleeve depending on individual differences of the crankcases. If there is interference,the crankcase needs processing.
○ Setting the cylinder in place with a dowel pin, attach it to the crankcase, and check for the interference with the crank cases.
○ In case there is interference, see where the cylinder interferes with the crankcases.
○ Referring to the service manual, disassemble the crankcases, and scrape the interferring part with a file or a hand grinder but bitby bit not to over-scrape the portion.
○ In scraping, be careful not to let the cutting chips and shavings into bearings and other parts. After the processing of thecrankcases, clean them.
○ After disassembling the crankcases, check every component referring to the service manual.

CO

Caution: Do inspection of every component and replacement of consumables, with utmost care.

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

7mm

PY

7mm

・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 crankshaft.
∴ Shaft direction:If larger than 0.10 mm, replace it.
Bearing direction: If larger than 0.05 mm, replace it.

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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 the
kit 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.)○ Attach the cam chain guideto the cylinder.

Mark side up
Mark side up

Top ringCirclipring-end gap

20°
20°

20°

Notch in the piston hole
Second ring
（Black）○ Remove the cloth used to plugholes.
○ Thoroughly degrease thecylinder base of the crankcase,and fit a dowel pin into thedowel pin hole.

Siderail

Expander

25mm

25mm

PistonCOTop ring
Second ringSide rail

PistonExpander○ 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

Notch in the piston hole

○ 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.

Pay attention to the crosssection as well!!

○ Apply molybdenum solution to
the piston pin and the holes on
the connecting rod small end.

○ Fix a cylinder gasket of thekit into the cylinder base of
the crankcase.

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

○ Apply engine oil to the insideof the cylinder.

○ Install the cylinder headfollow to the SuperHead + R
instruction manual.

○ Install the cylinder into thestud bolt with compress thepiston ring.
Caution: Do the work with care
not to damage thepiston rings.

○ 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.

2022.2.22

01-04-0105,01-02-0102※ 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.

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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
59mm

Stroke length
50.6mm

Displacement
138.3cm3

Compression ratio
13.0:1

Reference Value List for Cylinder and Piston Maintenance
Item
Service limit
Remarks
Cylinder Distortion
0.05mmMore replace
Internal diameter
59.10mmMore replace
PistonExternal diamter（7.5 mm from the hem of a skirt)
58.90mm
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
2ND
0.50mmMore replace
OIL(Side rail)
0.90mmMore replace
Clearance between cylinder and piston
0.12mmMore replace
Clearance between piston and pin
0.05mmMore replace

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.

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INSPECTION / SERVICE LIMITS○ Inspection of Cylinder
・Check the inside of cylinder for wear and damage.
・Measure the internal diameters of the cylinder bore at 6 positions;at the piston pin angle and at the right angle to it (X-Y) eachat upper, middle and lower parts of the cylinder bore.
Treat the largest value as its internal diameter.
∴φ 59.10mm or more replace
Calculate the clearance between a cylinder and a piston.
YIN・Calculate the clearance between the cylinder and the piston.
∴ 12.98mm or below replace

EXX

Upper

CO・Measure the internal diameter of the piston pin hole.
∴ 13.03mm or more replace

MiddleLower

Micrometer・Check the top surface of the cylinder for scratches and damages.
・Check the cylinder top surface for distortion with a straightedge and thickness gauge.
∴ Usage Limit：0.05mm or more replace○ Inspection of Piston Ring

Straight edge

Thickness gauge○ Inspection of Piston

・Calculate the clearance between the piston and the piston pin.
∴ Clearance 0.05mm or more replace

・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:0.50mm or more replace
2ND:0.50mm or more replace
OIL Side rail:0.90mm or more replace

PY

・Clear the piston of the remaining carbon residue.
・Fit a piston ring into the piston, and measure the clearancebetween the piston ring and ring groove with a thickness gauge.
∴ TOP:0.09mm or more replace
2ND:0.09mm or more replace
Piston ring
Push inPistonring● Supplement

・If you intend to change the piston with a new one, you can orderthe one from us by the number stamped on the top of the piston.

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 pin holes.
∴φ 58.90mm or below replace

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

Micrometer
90°

7.5

Example:13101-CDR-T00

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.

Measurepoint・Calculate the clearance between the cylinder and the piston.
∴ Clearance 0.12 or more replace
2022.2.22

01-04-0105,01-02-0102〔Ref.〕Running-in
Up to 5000rpm / approx.150kmC/2