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COPY

‑B5‑

Sep./12/ 12

About Optional Clutch Parts:

After removing a thermostat hole cap, install the 

thermo unit.

For details, see the Instruction Manual for the 

  

thermo unit.

The thermo unit alone does not function.

(Installation of thermo unit)

Oil Cooler Installation

In case a thermo unit is to be installed:

1.

 Install a thermo unit.

2.

Unfasten two oil plug bolts, and install an adapter

  

suitable for the kind of hose you will use. Then 

  

connect the hose.

 ※

Please see the instruction manual for the thermo

  

unit.

 ※

Please see the instruction manuals for the oil 

  

cooler kit and the adapter.

Rubber hose

Slim-line hose

Allegri’s hose

In the case of not installing the thermo unit

1.

Detach the thermostat hole cap, and fit a

  

supplied oil hole plug into the oil hole.

2.

Apply engine oil to the O-rings of the thermostat 

  

hole cap, and tighten the hole cap to the

  

specified torque.

  

Torque:  13 N

m (1.3 kgf

m)

3.

Unfasten two oil plug bolts, and fit an adaptor to 

  

match the hose to be used.  And connect the hose.

 ※

For details, see the Instruction Manuals for an Oil

  

Cooler Kit and an Adaptor.

IN OUT

Thermostat hole cap

Oil hole plug

In case an oil cooler is not installed:

NEVER install a thermo unit or an oil hole plug. And in

case the thermo unit and / or an oil hole plug is

installed, DO be sure to remove it or them.

Relevance of Front Fork and Tire

  ☆

For 10-inch tire, clamp the top bridge at the 

   

highest point of the front fork.

  о

Before installing, make sure that no

   

interference occurs when the front fork is fully

   

bottomed.

  о

If the interference occurs, use the low profile

   

tire in order not to interfere.

  о

Clamp the top bridge at the highest point of the

   

straight portion to avoid the tapered portion of

   

front fork.

  ※

Before installing, make sure that no

   

interference occurs when the front fork is fully

   

bottomed.

 ○φ

27Upright Front Fork

 ○φ

30 Upright Front Fork

Clearance

Tapered portion

Caution

There is a possibility

     

that the engine is 

     

damaged because

     

the oil passage will

     

be blocked when 

     

the thermo unit or an

     

oil hole plug is

     

installed.

Caution

NEVER install a 

  

    

thermo unit or an oil

    

hole plug if you do 

    

not connect an oil 

    

hose to the clutch 

    

cover.

    

There is a possibility

    

that the engine is 

    

damaged due to the

    

oil passage

    

blockage.

Summary of Contents for 01-00-9202

Page 1: ...ads This kit is compatible with the above mentioned compatible models ONLY Note Do Not use this product for other models than listed above The cylinder length of this complete engine is longer than th...

Page 2: ...these damaged parts as they are could lead to accidents When you notice something abnormal with your motorcycle while riding immediately stop riding and park your motorcycle in a safe place to check w...

Page 3: ...m crankcase oil line in order to cool the piston Use of Oil Jet Use of Wet Multiple Disk Clutch We have installed a multiple disk clutch with 5 disks onto the transmission main shaft so it can respond...

Page 4: ...00 1 11 Braided hose 8 x 1 m 1 1 12 Hose clamp 13 1 2 2 13 Hyper CDI 1 05 03 0003 1 14 Thumb screw 1 00 01 0254 2 15 Snap ring 6mm 4 00 01 0255 5 16 Rebuilt gasket set 1 06111 4SS T20 1 17 Spark plug...

Page 5: ...ecommend more frequently maintenance than the maintenance period Type 4 cycle gasoline Displacement 147 6cc Number of cylinder and arrangement Horizontal single cylinder Cooling method Air cooling Val...

Page 6: ...igh load running which keeps oil at appropriate temperatures and prevents such troubles as oil film shortage at high temperatures In case you use the breather cap be sure to use an oil catch tank at t...

Page 7: ...r the numbers are the narrower the durations are With these camshafts the output power will produce more to low to mid rpm range The output features are different from each size When purchasing our op...

Page 8: ...t the plain washer into the release pinion Attach the adjuster of the clutch cable to the cable receiver and attach the cable end to the arm so the notch on the split clamp of clutch release arm faces...

Page 9: ...ed main jet 110 and slow jet 35 and then a float chamber Detach a top cover of the supplied carburetor and pull out the spring and throttle valve Pass the inner cable of the throttle cable through the...

Page 10: ...he spring fix the top cover and all to the throttle valve Fix the throttle valve to the carburetor by aligning a notch on the throttle valve with the throttle stop screw In the case of VM26 Insert the...

Page 11: ...n the plug And tighten the plug After the adjustment or setting carry out a shakedown about 30 to 50 km and check the valve clearance again IN 0 08 mm EX 0 08 mm Install an exhaust muffler according t...

Page 12: ...e the Instruction Manuals for an Oil Cooler Kit and an Adaptor Thermostat hole cap Oil hole plug In case an oil cooler is not installed NEVER install a thermo unit or an oil hole plug And in case the...

Page 13: ...PIckup pulse Ignition AC output Neutral Switch Racing use A C G e n e r a t o r f o r S p a r k A C G e n e r a t o r f o r L i g h t i n g TAKEGAWA C D I Green Black Red Black Red Blue Yellow Green...

Page 14: ...e sure to use a torque wrench and strictly keep the specified torque Gap Benchmark 0 6 0 7 mm Electrode section Gap Standard NGK ER8EH DENSO Y24FER C Plug with high thermal value NGK ER9EH DENSO Y27FE...

Page 15: ...ut Caution Be sure to follow the specified torque Adjust the Valve Clearance Unfasten three screws holding the leftside cover to detach the leftside cover Remove the generator cover by unfastening the...

Page 16: ...deactivated EX 0 05 0 08 when cold Tighten the adjusting nut to the specified torque Turn the flywheel and adjust to the top dead center TDC Marks Remove the thumb screw Re install the left side cover...

Page 17: ...ed At idling Give the air screw a right turn The air fuel mixture gets dense Give the air screw a left turn The air fuel mixture gets lean Loosen the tightened air screw back to the 1 5 turn position...

Page 18: ...0133 Main jet 90 00 03 0110 Main jet 150 00 03 0134 Main jet 92 00 03 0111 Main jet 152 00 03 0135 Main jet 95 00 03 0112 Main jet 155 00 03 0136 Main jet 98 00 03 0113 Main jet 158 00 03 0090 Main j...

Page 19: ...D auto decompression cam shaft 25 30D auto decompression cam shaft 01 08 0141 01 08 0142 01 08 0143 01 08 0144 Racing C D I Magnet Kit 05 02 0511 Excellentstartupperformancebecauseofignitionatlow revo...

Page 20: ...incorporated This cooler body has an oil cooler plate and guard as standard equipments In addition the bracket mounting is integrated with the oil cooler plate so that you can use the oil outlet upsid...

Page 21: ...ing force generating mechanism of free valve type andreducestheshockwhenthefrontshocksreboundandcompress Ourfrontforkincreasesthestabilityofstrokebyusingthedampedforce generating mechanism of free val...

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