Kit Instruction Manual

9
-A’1- Nov ./18/ ’10 Please read the following before the installation. Features 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 instruction manual should be retained for future reference. Idling, sudden acceleration, and sudden engine braking will put a heavy load on the engine, which may result in crank shaft damage and engine breakage in the worst case. Quick starting and sudden acceleration Please note: Illustrations and photos may vary from actual hardware. Thank you for purchasing one of our TAKEGAWA's products. Please strictly follow the instructions to install and use the products. Before installing the products, please be sure to check the contents of the kit. If you have any questions about the products, please kindly contact your local TAKEGAWA dealer. This kit is our Super Head 4valve for exclusive use with KSR110, KLX110 and KLX110L. It has all new designs such as 4 valves(two intakes, two exhausts), the included angle of valves or port designs. Roller bearings are applied at the shovel portion of valve rocker arm, and we utilize forged aluminum rocker arm to reduce the increased weight with the bearings, so that the weight remains the same. As the result, all the functions make it possible to provide higher output power in high-range. 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 in the manual. This kit is designed for exclusive use with the above-mentioned model types with specified applicable frame Nos only, and in the vehicles equipped with the special bore-up exclusively for this kit. Please take note that this kit cannot be mounted on other types of motorcycles or compatible with other bore-up than the special one for this kit. Installation of this product requires removal and reinstallation of an engine, and disassembly of a clutch. Please prepare genuine service manual for the above-mentioned applicable models, and work with enough care following instructions in the service manual. Besides, this instruction manual, as well as service manual, is prepared for those who have acquired basic skill and knowledge in tuning. We recommend those who are technically inexperienced or without right tools to ask a technically-trustworthy specialist shop to do the work for you. We shall be held free from any kind of warranty whatsoever of products other than this product if the any defect takes place on the other products than this one after the installation and use of this product. We do not have any information or service data on the combination of our products and other manufacturer’s products. A serial number is stamped on the cylinder head. You may be requested to inform us of the number when ordering parts. Some of bolts and nuts will be reused. However, be sure not to use the worn-down or severely-damaged ones and replace them with the new ones. Do not use liquid seals, which may oppilate oil's passage; it may break the engine in the worst case. Be sure to always use premium unleaded petrol. And make sure to check what kind of gasoline is remaining in the fuel tank. Whenever regular gasoline is left in the fuel tank, always replace it with high-octane gasoline. Determine the heat value of a spark plug depending on how much it is burnt. Please be informed that what we can safely say is that the ignition system of this kit is compatible with ours and stock ignition systems, because no data is available with us on the compatibility with other ignition systems. So never use this kit together with any other ignition system to avoid technical troubles. Install an oil cooler when necessary. Engine oil must be API SF or higher class, such as SAE 10W-40 / 15W-50, which are our recommendations. Change the sprocket with the one to meet the vehicle’s power and specifications. In case you have purchased this kit for use just as a cylinder head kit, you cannot use this kit in this way. If you have not purchased”special engine parts compatible with this kit,”please purchase separately the special parts referring to the”Reference data on bore-up kit.” This kit is only compatible with the engine parts we recommend. If the parts are not compatible, please replace them with the engine parts we recommend. This product is designed for exclusive use with off highway or closed road. NEVER use on public roads. Please drive safely and follow the local traffic laws. Work only when the engine and the exhaust system are cool, below 35 degrees C, to avoid burns. Prepare appropriate tools and work properly to avoid the breakage of parts or injuries. As some products and frames have sharp edges or protruding portions, work with your hands protected to avoid injuries. Always use new gaskets and sealings. (Worn or damaged parts may cause engine troubles.) The following show the envisioned possibility of injuries to human bodies and property damage as a result of disregarding the following cautions. Caution Item No. :01-03-0121 Model types with applicable cylinder heads and frame Nos KSR110 KLX110 KLX110L KL110A-000001 LX110A-000001LX110A-A08133LX110D-A72046Kit Instruction Manual

Transcript of Kit Instruction Manual

COPY

-A’1- Nov./18/’10

Please read the following before the installation.

~ Features ~

◎ 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 instruction manual should be retained for future reference.

Idling, sudden acceleration, and sudden engine braking will put a heavy load on the engine, which may result in crank shaft damage and enginebreakage in the worst case.

Quick starting and sudden acceleration

◎ Please note: Illustrations and photos may vary from actual hardware.

・Thank you for purchasing one of our TAKEGAWA's products. Please strictly follow the instructions to install and use the products.・Before installing the products, please be sure to check the contents of the kit. If you have any questions about the products, please kindly contact your local TAKEGAWA dealer.

○ This kit is our Super Head 4valve for exclusive use with KSR110, KLX110 and KLX110L. It has all new designs such as 4 valves(two intakes, two exhausts), the included angle of valves or port designs. Roller bearings are applied at the shovel portion of valve rocker arm, and we utilize forged aluminum rocker arm to reduce the increased weight with the bearings, so that the weight remains the same. As the result, all the functions make it possible to provide higher output power in high-range.

◎ 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 in the manual.◎ This kit is designed for exclusive use with the above-mentioned model types with specified applicable frame Nos only, and in the vehicles equipped with the special bore-up exclusively for this kit. Please take note that this kit cannot be mounted on other types of motorcycles or compatible with other bore-up than the special one for this kit.◎ Installation of this product requires removal and reinstallation of an engine, and disassembly of a clutch. Please prepare genuine service manual for the above-mentioned applicable models, and work with enough care following instructions in the service manual. Besides, this instruction manual, as well as service manual, is prepared for those who have acquired basic skill and knowledge in tuning. We recommend those who are technically inexperienced or without right tools to ask a technically-trustworthy specialist shop to do the work for you.◎ We shall be held free from any kind of warranty whatsoever of products other than this product if the any defect takes place on the other products than this one after the installation and use of this product.◎ We do not have any information or service data on the combination of our products and other manufacturer’s products.◎ A serial number is stamped on the cylinder head. You may be requested to inform us of the number when ordering parts. ◎ Some of bolts and nuts will be reused. However, be sure not to use the worn-down or severely-damaged ones and replace them with the new ones.◎ Do not use liquid seals, which may oppilate oil's passage; it may break the engine in the worst case.◎Be sure to always use premium unleaded petrol. And make sure to check what kind of gasoline is remaining in the fuel tank. Whenever regular gasoline is left in the fuel tank, always replace it with high-octane gasoline.◎ Determine the heat value of a spark plug depending on how much it is burnt.◎Please be informed that what we can safely say is that the ignition system of this kit is compatible with ours and stock ignition systems, because no data is available with us on the compatibility with other ignition systems. So never use this kit together with any other ignition system to avoid technical troubles.◎ Install an oil cooler when necessary.◎ Engine oil must be API SF or higher class, such as SAE 10W-40 / 15W-50, which are our recommendations.◎ Change the sprocket with the one to meet the vehicle’s power and specifications.◎In case you have purchased this kit for use just as a cylinder head kit, you cannot use this kit in this way. If you have not purchased”special engine parts compatible with this kit,”please purchase separately the special parts referring to the”Reference data on bore-up kit.”◎ This kit is only compatible with the engine parts we recommend. If the parts are not compatible, please replace them with the engine parts we recommend.

・This product is designed for exclusive use with off highway or closed road. NEVER use on public roads. Please drive safely and follow the local  traffic laws. ・Work only when the engine and the exhaust system are cool, below 35 degrees C, to avoid burns. ・Prepare appropriate tools and work properly to avoid the breakage of parts or injuries. ・As some products and frames have sharp edges or protruding portions, work with your hands protected to avoid injuries. ・Always use new gaskets and sealings. (Worn or damaged parts may cause engine troubles.)

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

Item No.:01-03-0121Model types with applicable cylinder heads and frame NosKSR110KLX110

KLX110L

:KL110A-000001~:LX110A-000001~:LX110A-A08133~:LX110D-A72046~

Kit Instruction Manual

COPY

-A’2- Nov./18/’10

① About fuel: Whenever regular gasoline is remaining in the fuel tank, always replace it with high-octane gasoline.② Change of a sprocket:◇ The installation of this product will increase the power of your vehicle. So use of a normal sprocket will result in severe wears of parts because of too low gear, not only adversely affecting the engine life, but also   

 breaking the engine in the worst case. Please replace the sprocket with the high-geared one.

●Cautions before riding:

●Others:

● A serial number is stamped on the cylinder head just for the sake of    administration. You may be requested to inform us of the number when   ordering repair parts. In case you are not able to order parts because you do not have the repair parts numbers or for other reasons, please place an order in the following way.

☆ Make a note of the number stamped on the left side of the cylinder head. Head No.: KSS-00001 Example of ordering → Super Head Kit, repair part            Head No.: KSS-00001 → Intake valve            Qty:1

● For those who have purchased a cylinder head as a single item, some   products are available from us to meet engine displacement and other    requirements. Please study to install the products, referring to “Reference data on bore & stroke-up kit.” For more details about the products or     queries, please contact your dealer.

●About cam shaft

◇ If you have purchased a cylinder head kit alone, a special camshaft is   needed separately. Camshafts with a few kinds of profiles are available from us to meet different uses and engine displacement. Even if you have purchased a full kit, you can study to use them as an optional extra in   

 addition to camshafts included in the full kit. For more information, please refer to page 3.

●Upper limt of revolutions:

Head No. stamped hereKSS-00***

KSS-00000

Oil cooler:◇ The installation of this product increases the heat release value of the   engine, set off by the increase in power. For a long-time high-load running, we recommend you to install an oil cooler kit which keeps oil at appropriate temperatures and prevents such troubles as oil film shortage at high temperatures.

◇ Upper limit of revolutions varies depending on the installed cam shafts,   etc. Referring to the camshaft comparison graph on page A3, install a revolution counter to make sure that you drive the engine at revolutions   below the upper limit.◇Take note that idling and sudden acceleration in the 1st and the 2nd gears particularly tend to exceed the upper limit of revolutions. Over revolutions  will result in nonsmooth revolutions of the engine, not only adversely    affecting the engine life, but also breaking the engine in the worst case.

◇We have an optional titanium valve spring retainer for this Super Head.   Titanium valve spring retainer is about 30% lighter than steel retainer. CrN coating which has surface hardness more than HV1000 finishes on surface for added impact resistance and wear resistance. Description: 00-01-0135(4 pieces)

●Optional valve spring retainer

・Those who are technically unskilled or inexperienced are required not to do the work.  (Improper installation due to unskilled technique or lack of knowledge could lead to parts breakage and consequently to accidents.) ・Before doing work, place the motorcycle on level ground to stabilize the position for safety to avoid the motorcycle overturning. ・Always start the engine in a well-ventilated place, and do not turn the engine on in an airtight place.  (Otherwise, you will suffer from 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.) ・Always use a torque wrench to tighten bolts and nuts securely to the specified torque to avoid these parts getting damaged or loose. ・Never use the parts unspecified by us. (This may lead to parts breakage and consequent accidents.) ・If you find damaged parts when inspecting or performing maintenance of your motorcycle, do not use these parts, and replace them with new ones. (The continued use of these damaged parts could lead to accidents.) ・When you notice something abnormal with your motorcycle, stop riding immediately and park your motorcycle in a safe place to avoid an accident. ・Before riding, always check such parts as screws for loose. If you find loose ones, screw them securely up to the specified torque to avoid parts coming off. ・Check or carry out maintenance of parts correctly according to the procedures in the instruction manual or a service manual.  (Improper checking or maintenance could lead to accidents.) ・Fuel must be high-octane gasoline. (Otherwise, troubles such as engine knocking may cause accidents.)

The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the followingcautions.

Warning

COPY

-A’3- Nov./18/’10

●Engine parts of our recommendation:

●About optional cam shaft

☆Lists of camshaft comparison data NB) As these are the data measured on a Dyno Jet, the data differ from the actual driving. Please see them just as a reference.   The engine power varies significantly depending on the temperatures.

3 4 5 6 7 8 9 10 11 12

22

24

20

18

16

14

12

10

8

6

4

2

20

18

16

14

12

10

8

6

4

2

03 4 5 6 7 8 9 10 11 12 13 14

3 4 5 6 7 8 9 10 11 12 13 14

22

20

18

16

14

12

10

8

6

4

2

0

KSR178cc SuperHead 4VALVE SCUT KEIHIN PE28 Racing Exhaust System

SAE

Powe

r(PS

)

RPM(x1000)

KSR138cc SuperHead 4VALVE KEIHIN PE28 Racing Exhaust System

SAE

Powe

r(PS

)

RPM(x1000)

SAE

Powe

r(PS

)

KSR125cc SuperHead 4VALVE KEIHIN PE28 Racing Exhaust System

10-15 cam

15-20 cam 25-30 cam20-25 cam10-15 cam

15-20 cam

25-30 cam

20-25 cam

15-20 cam25-30 cam

20-25 cam

10-15 cam15-20 cam

25-30 cam

20-25 cam10-15 cam

※ This kit is only compatible with the engine parts we recommend. If the parts are not the same as below, please replace them with the engine parts we recommend.

○ Several kinds of camshaft for this kit are available. Choose the suitable displacement and camshaft for your ride in the below chart and enjoy the ride.

Included camshaft 10/15D 01-08-0128Option 15/20D 01-08-0129Option 20/25D 01-08-0130Option 25/30D 01-08-0131

125cc kit

option 10/15D 01-08-0128included camshaft 15/20D 01-08-0129option 20/25D 01-08-0130option 25/30D 01-08-0131

138cc kit

option 10/15D 01-08-0128option 15/20D 01-08-0129included camshaft 20/25D 01-08-0130option 25/30D 01-08-0131

178cc kit

○ About the descriptions of camshaftsThe bigger the camshaft numbers of XX/YY are, the wider the duration is. It means to provide higher output power in high range and control the output powerin low to mid ranges. While the smaller their numbers are, the narrower the duration is.The output power is controlled in top range and the higher output power is provided in low to mid ranges.The characteristics of output power are different. Our kits include the suitable camshaft for each displacement.Please choose a suitable camshaft for your riding purpose referring to the camshaft data chart when you purchase our optional camshaft. Furthermore, theengine output power will be changed unexpectedly with specs such as exhaust systems, inlet pipe length, carburetor diameter, compression ratio, ignitionsystem, ignition timing, octane value or with natural phenomenon such as ambient temperature or atmospheric pressure.

Heavy-duty clutch spring kit 02-01-0296

Keihin PE28 carburetor kit 03-05-0022Mikuni VM26 carburetor kit 03-05-0021

KLX110 Keihin PE28 carburetor kit 03-05-0028KLX110L Mikuni VM26 carburetor kit 03-05-0027

CarburetorKSR110

Recommended Part

Stock C.D.I. ClutchIgnition system

15-20 cam 25-30 cam20-25 cam10-15 cam

RPM(x1000)

15-20 cam 25-30 cam20-25 cam10-15 cam

COPY

-A’4- Nov./18/’10

No. Part Name Qty Repair Part No. In packs of No. Part Name Qty Repair Part No. In packs of 1 Cylinder head ASSY. 1 06120-KSS-T01 1 10 Manifold gasket 1 00-03-0012 22 Intake rocker arm COMP. 1 14430-KSS-T11 1 11 Exhaust pipe gasket 1 00-01-0035 23 Exhaust rocker arm COMP. 1 14420-KSS-T11 1 12 Plug cap rubber 1 30701-D4H-T00 14 Cam stopper plate 1 12211-KSS-T00 1 13 Stud bolt 4 00-01-0131 45 Side cover 1 14 Valve adjusting screw 4 16 Inspection cap 2 15 Valve adjusting nut 4 17 Oil line 1 15510-KSS-T00 1 16 Socket cap screw, 6X15 6 00-00-0042 108 Side cover O-ring 1 12395-KSS-T00 1 17 Truss head machine screw, 5x10 2 00-01-0133 49 Inspection cap O-ring 2 91302-KSS-T00 1 Alumi Special (5 g) 1 00-01-0001 1

00-01-0132

No. Part Name Qty Repair Part No. In packs of No. Part Name Qty Repair Part No. In packs of A Intake valve 2 14711-KSS-T10 1 E Valve spring 4 14751-KSS-T10 1B Exhaust valve 2 14721-KSS-T10 1 F Valve spring retainer 4 14770-KSS-T10 1C Valve spring seat 4 14775-KSS-T10 1 G Valve cotter 8 00-01-0018 2D Valve stem seal 4 00-01-0015 2 H Stud bolt 2 00-01-0134 2

In packs of 12237-KSS-T10 Valve guide O / S 1Over-sized valve guide for repair

~ Kit Contents ~

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

Titanium valve spring retainer In packs of 00-01-0135 4

O.P

※Please order repair parts with the Repair Part Item No. Without the repair part item No., we may not be able to provide the correct parts. Some parts are only available as a set. Please order them with the set number.

CDE

FG

CD

FG

89

10

13

12

11

14

1514

15

16

16

16

17

14

15

14 15

17

16

16

16

00―01―1031

89

01―13―8010

00―01―1030

COPY

- B ’1 - Nov./18/’10

~ Cylinder Head Installation Procedures ~

○ Degrease well the upper surface of the cylinder.

Dowel pin

N E W

O I L

Align themounting point.

Align themounting point.

Headnut

Head bolt

Headnut

Headnut

Headnut

Head bolt

MO OIL

○Remove a rocker arm shaft in the stock cylinder head.

○Apply an engine oil to the included valve adjusting screws and install them on the included rocker arms.

○ Install the rocker arms on Super Head. Apply molybdenum oil to the stock rocker arm shaft and install both IN and EX rocker arm shafts.

○ Install the special cam shaft. Apply engine oil to the bearing.

○ Install the special camshaft on the cylinder head. Note: Make sure that both of the cam lobes (IN, EX) should be faced to the combustion chamber.

○ Install the cam stopper plate (included in the kit) on Super Head using two screws. Note: Make sure that both sides of cam stopper and notches of rocker arm shaft should be aligned, and   tighten the screws to the specified torque. Caution: Apply the specified torque. T=5.2 N・m (0.53 kgf・m)

○ Install the cylinder head gasket (included in the kit) on the cylinder.

○ Install the dowel pin into the cylinder.

○Slightly apply “Alumi Special”, the   heat-resistant lubricating paste, to the threaded portion of head stud, and loosely tighten the head nut and bolt.

○Tighten 4 head nuts and 2 head bolts in a numerical order in the following figure in a crisscross pattern in two or more steps to the specified torque. Caution: Apply the specified torque. For head bolt:  T=12 N・m (1.2 kgf・m) For head nut:  T=22N・m (2.2 kgf・m)

○ Install the cylinder head.

Bending angle 45°

○Install the included spring into the slide shaft at the center of camshaft.

Bending angle 25°

○ Attach the cam chain to the cam sprocket. When the “T” mark on the flywheel is aligned with the   notch on the crankcase, the “T” mark on the cam sprocket must   be aligned with the notch on the cylinder head.

Notch

“T” mark

“T” mark

Notch

●For KSR110 and KLX110

○Remove the banjo bolt and copper washer from the stock oil line and install the included oil line. Tighten the banjo bolt to the specified torque. Caution: Apply the specified        torque.  T=15N・m (1.5 kgf・m)

COPY

-B’2- Nov./18/’10

○ Adjust the valve clearance with an adjusting screw. IN:0.05 ~ 0.08 (When cold.) EX:0.05 ~ 0.08 (When cold.)

Cap bolt

○ Attach the snap ring in the shaft   groove. Caution: Do not expand the snap ring     more than necessary. WARNING : Always use a NEW snap       ring.       NEVER reuse the old         snap ring.

○Tighten the adjusting nut to the   specified torque. Caution: Apply the specified        torque.  T=8.8 N・m (0.9 kgf・m)

○ Unscrew the thumb screw.

Cap screw

Weight

Collar

Thumb screw

○Install the 6x20 cap screw into   the collar and the weight.

○ Install a 6mm snap ring and a plate using with the supplied 3x28 thumb screw and attach them to the tip of the shaft that is included in the kit.   Then pull them outside.

○Check that a push rod of a cam chain  tensioner is locked.○ Install the cam chain tensioner with  two screws, and tighten them to    the specified torque. Caution: Apply the specified torque.  T=5.2 N・m (0.53 kgf・m)

○Remove a cap bolt on the cam chain tensioner, and rotate the stopper (located inside) counterclockwise to unlock the push rod.

○Tighten the cap bolt of the cam chain tensioner to the specified torque. Caution: Apply the specified torque.  T=5.2 N・m (0.53 kgf・m)

○Check to see if the “T” marks and the notches on flywheel and cam sprocket are aligning respectively.

※When adjusting the valve clearance, pull thumb screw at the center of the camshaft outside not to work the decompression device on the exhaust side.

○ Turn the crankshaft counterclockwise twice and make sure that valve clearance remains the same. If not the same, redo the     procedure of adjustment.

●For KLX110L

Notch

“T” mark

Notch

Thumb screw

Notch

“T” mark

○Install the cam chain on the supplied cam sprocket. While aligning a “T” mark of the   flywheel and a notch of the    crankcase, align a notch of the   cam sprocket with a notch of the cylinder head.

○ Fasten and tighten the 6x12 cap screw on the lower hole (EX) of the cam sprocket to the specified torque. Caution: Apply the specified torque. Torque: 12 N・m (1.2 kgf・m)

○Install the above parts into the   upper hole(IN) on the cam     sprocket (as shown below), and tighten the 6x20 cap screw to the specified torque. Caution: Apply the specified torque.    Torque: 12N・m         (1.2 kgf・m)

○ Put a cap screw 6 x 20 into the   decomp collar 2, and put them in the weight.

Decomp collar 2 Cap screw

Weight

Cam sprocketDecomp guide

WeightDecomp collar 2

Cap screw,6x20

Cap screw,6x12

○Install the decomp guide, the thicker side of the screw mounting is the   upper side (to the IN side), the thinner side is the lower side (to the EX side), and attach a cap screw 6 x 12 to the lower side (the EX side). Then tighten them to the specified torque. Caution: Apply the specified torque. Cap screw,6x12 Torque: 8 N・m (0.8 kgf・m)※Make sure that the direction of    decomp guide must be correct.

○ Install successively with the    decomp guide, weight, and decomp collar 2 referring to the drawing, and tighten them to the specified torque. Caution: Apply the specified torque. Cap screw,6x20 Torque: 12 N・m (1.2 kgf・m)

COPY

- B ’3 - Nov./18/’10

☆ Engine Starting☆

○Check that an ignition key and a fuel cock are turned off.

○Continue kicking the starter for a   while to circulate the engine oil    throughout the engine.

○ Attach a drive sprocket and a drive chain.

○ Install the exhaust system referring to its installation manual.

○ Apply engine oil slightly to an O-ring on the side cover, and fasten the sprocket cover to the cylinder head with two socket cap screws to the specified torque. Caution: Apply the specified        torque.  T=7.9 N・m (0.8 kgf・m)

○ Apply engine oil slightly to an O-ring on the inspection cap, and fix the inspection cap with two   socket cap screws to the specified torque. Caution: Apply the specified        torque.  T=7.9 N・m (0.8 kgf・m)

6 7

○Degrease the generator cover   and the crankcase, and attach   two dowel pins with a new gasket.○ Fix the generator cover with nine bolts to the specified torque in a few steps in the numerical order. Caution: Apply the specified   

     torque.  T=5.2 N・m (0.53 kgf・m)

○ Fix the carburetor following the original instruction manual.

○ Referring to the service manual, mount the engine onto the frame. Caution: Be sure to follow the     instructions in the     service manual.

○Connect a coupler on the generator cover.

○Add the specified amount of engine oil.

 Caution: Choose the heat value of a     spark plug by inspecting       how much it is burnt.

○ Replace the stock plug cap rubber with the included plug cap rubber.

○ See if there is anything wrong including strange sounds.

○Do the break-in again of 100 to 150 km.

○Attach the plug cap to the spark plug.

○Turn on the fuel cock and ignition   key to start the engine. Warning: Be sure to start the engine     in a well-ventilated place.

○ If everything is OK, do the break-in of about 30 to 50 km. Then check   the valve clearance. Caution: The engine and exhaust       system must be cool when     checking the valve     clearance.

○ After the break-in, see if there is   nothing wrong like strange sounds or blow-by gas. If something wrong is found,     disassemble the engine again to   check every part of it. Warning: Never reuse the unusable     parts.

○ Install the shift pedal. Caution: Apply the specified torque.  T=5.2 N・m (0.53 kgf・m)

○ Install the sprocket cover. Caution: Apply the specified torque.  T=5.2 N・m (0.53 kgf・m)

    T: 10 N・m (1.0 kgf・m)

оLightly apply “Aluminum Special”, the heat-resistant lubricating agent, to the threaded portion of the spark   plug and install it. Caution: Use the correct plug. Caution: Be sure to tighten to the     specified torque.     NGK : ER 8 EH

     Denso : Y 24 FER↑

↑Heat value

Heat value

COPY

Oct./01/’10

01

―0

3―

01

21

シリンダーを選択

☆0

1―

03

―0

12

1シ

リン

ダー

ヘッ

ドキ

ット

のみ

で購

入さ

れた

場合

、こ

の参

照表

にて

専用

パー

ツを

検討

して

下さ

い。

If you have purchased a cylinder head kit only (Item N

o. 01-03-0121), please study to install these special parts referring to this reference data.

Select a cam

Select a cylinder

00

―0

1―

00

58

12

5c

13

8c

01

―0

4―

01

19

125cc Cylinder K

it

01

―0

4―

01

18

01

―0

2―

01

42

12

5c

c 

φ5

01

―0

2―

01

43

13

8c

c 

φ5

138cc Cylinder K

it01

―0

4―

01

20

178cc SC

UT C

ylinder Kit

17

8c

AU

TO D

EC

OM

P01-08-012801-08-012901-08-013001-08-0131 KSR110

/ KLX110

ボア

アッ

プ参

照表

(125cc,138cc,178cc)

KS

R110 / K

LX110 R

eference d

ata on

bo

re-up

kit (125cc,138cc,178cc)

10/15D cam

shaft15/20D

camshaft

20/25D cam

shaft25/30D

camshaft

カム

を選

17

8c

c 

φ6

COPY

Oct./01/’10

01

―0

3―

01

21

シリンダーを選択

☆0

1―

03

―0

12

1シ

リン

ダー

ヘッ

ドキ

ット

のみ

で購

入さ

れた

場合

、こ

の参

照表

にて

専用

パー

ツを

検討

して

下さ

い。

If you have purchased a cylinder head kit only (Item N

o. 01-03-0121), please study to install these special parts referring to this reference data.

Select a cam

Select a cylinder

00

―0

1―

00

58

12

5c

13

8c

01

―0

4―

01

19

125cc Cylinder K

it

01

―0

4―

01

18

01

―0

2―

01

42

12

5c

c 

φ5

01

―0

2―

01

43

13

8c

c 

φ5

138cc Cylinder K

it01

―0

4―

01

20

178cc SC

UT C

ylinder Kit

17

8c

cA

UTO

DE

CO

MP

01-08-013601-08-013701-08-013801-08-0139

KLX110Lボ

アア

ップ

参照

表(

124cc,138cc,178cc)K

LX

110L R

eference d

ata on

bo

re-up

kit (124cc,138cc,178cc)

10/15D cam

shaft15/20D

camshaft

20/25D cam

shaft25/30D

camshaft

カム

を選

17

8c

c 

φ6