raider 150 big bore

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HARLEY DAVIDSON EFI SCREAMIN' EAGLE BIG BORE EFI STAGE 2 KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 29-01-2011

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INSTALLATION Installation of this kit is divided into six steps: 1. Big-Bore Cylinder and Piston Conversion 2. High Performance Camshafts 3. High Performance Clutch Diaphragm Spring 4. High Performance Air Cleaner 5. Calibrate the ECM 6. Exhaust NOTES This Big-Bore Stage 2 kit is intended for High Performance applications only. This engine-related performance part is legal for sale or use in California on pollution-controlled motor vehicles. Engine-related performance parts are intended for the experienced rider only. -J04173 1 of 5 The air cleaner contained in these kits is designed to perform with these kits only. Any other combination of components is not confirmed to be legal for street use. The Product Information Label contained in this kit is required in the state of California only. This label is required to aid in passing the California Smog Check Program. Place the Product Information Label on the right side of the frame, directly beneath the VIN sticker. Do not place the label on motorcycles other than those specified in the Instruction Sheet. Gaskets provided in the 1690 conversion kit eliminate the need for original head gasket O-rings. For this reason, DO NOT install the Original Equipment (OE) O-rings (Part Number 11273) to the top of cylinder dowels, or severe engine damage may occur. Big-Bore Cylinder and Piston Conversion NOTE Installation of this kit requires removal of the cylinder heads, cylinders and pistons. Refer to Section 3, ENGINE: STRIPPING MOTORCYCLE FOR SERVICE and TOP END OVERHAUL of the applicable Service Manual for instructions. High Performance Camshafts NOTE Installation of this kit requires removal and re-installation of the cam support plate. Refer to Section 3, ENGINE: BOTTOM END Cam Support Plate, Removal and Disassembly/Assembly (Camshaft, Camshaft Bearings) of the applicable Service Manual for instructions. Measuring Piston-to-Valve Clearance After installing non-stock cams, check piston-to-valve clear- ance. 1. Apply 1/8-inch (3 mm) layer of clay to crowns of pistons in areas where valves meet pistons. 2. Refer to the appropriate Service Manual and assemble the heads and valve train, and tighten cylinder studs to torque specified. 3. Turn engine through two complete revolutions by hand. 4. Remove heads and measure clay at its thinnest point. NOTE Clay must measure 0.080 inch (2.03 mm) at its thinnest point. If this measurement does not meet minimum thickness, depth of valve notches must be increased. The depth of the notches must not exceed 0.135 inch (3.43 mm). Measuring Valve-to-Valve Clearance NOTE Wait ten minutes before turning the engine after installing push rods. This allows tappets to bleed down and prevents you from bending push rods or valves. 1. Rotate the engine so that both valves of the front cylinder are partially open. Shine a light through the exhaust port and look through the spark plug hole to view the valves. Turn engine, if required, to the point where the exhaust evel sensor to the fuel pump with screw (3). Tighten the screw enough to seat the fuel sensor against the mounting tab e. Route fuel level sensor wiring under the fuel hose and connect the fuel level sensor to the low fuel switch connector on the fuel pump module. If necessary use the jumper harness (Figure 4, item 5). f. See Figure 2. Secure the fuel pump wires and con- nectors

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HARLEY-DAVIDSON V-ROD BIG BORE KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 31-10-2010

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The cylinder sleeves provided with the Wiseco V-Rod big bore kit have been finished honed to size and the piston to cylinder clearance has been set. Prior to installation, the sleeves must be washed in hot soapy water (not parts washer solvent) and dried. Coat the bore surface with motor oil and wipe it with a white towel. If the towel shows any remaining grit, repeat the hot soapy water washing process until the towel will only show clean motor oil. CAUTION: Test fit the cleaned sleeve (without O-Rings installed) into the engine block. Sleeve should drop into position. If sleeve will not easily drop into position, warm the engine block with a hair dryer until sleeve will drop into position. Remove sleeve, then continue installation procedures. From the bottom side of the sleeve, gently roll the 2-cylinder sleeve O-rings into the two grooves on each sleeve. Apply motor oil to the O-rings and gently install the sleeves into the block until bottomed. CAUTION: DO NOT ATTEMPT TO INSTALL SLEEVES WITHOUT LUBRICATING THE O-RINGS. FAILURE TO LUBRICATE O-RINGS COULD RESULT IN TORN OR DAMAGED O-RINGS THAT WOULD NOT BE EVIDENT UNTIL ENGINE WAS STARTED. INCORRECTLY INSTALLED O-RINGS CAN RESULT IN CATASTROPHIC ENGINE DAMAGE. NOTE: REFER TO THE OEM SERVICE MANUAL FOR ALL TORQUE SPECIFICATIONS PISTON RING PREPARATION Wiseco V-Rod pistons incorporate an advanced 2 ring system • The top ring is file-fit, and as such, requires that the end gap must be clearanced. The proper end gap clearance is .016-.018″ with the ring installed squarely in the bore. The top ring must be installed on the piston with the dot marking toward the top of the piston. • The oil ring is comprised of the expander and two rails. Install the expander first, and then the rails. Check to make sure the expander tips have not overlapped. It is not necessary to clearance the end gaps on the oil rails. The rails should be installed without modification. PISTON INSTALLATION The Wiseco V-Rod big bore kit is supplied with pistons that are front and rear cylinder specific. Install the front piston 4792M10795 in the front cylinder with the arrow facing the front of the engine. Install the rear piston 4793M10795 in the rear cylinder with the arrow facing the front of the engine. A piston ring compressor is required to install the pistons into the cylinders. Front of engine ➔ 4792M10795 ( Front piston) 4793M10795 ( Rear piston) FWD 4793M10795 FWD 4792M10795 For further information call the Wiseco Tech Line:

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TRIUMPH 750 BIG BORE CYLINDER AND PISTON SET FOR 650 TWINS INSTALLATION

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Filed Under (Triumph) by admin on 29-10-2010

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Step 1. Unpack your big bore kit and inspect the contents. There should be the following: 1. Cylinder x l 2. piston with wristpin x 2 3. Hepolite piston ring set x l 4. Special big bore head gasket Step 2. Thoroughly wash the cylinder bores with soap and water. Do not use solvent! Dry bores with air or a lint free towel and let completely air dry. This step is most important and will greatly extend the life of the pistons. Step 3. Following the procedure outlined in your service manual, drain the fuel tank, remove the exhaust system, fuel tank and carburetors. Have a catch basin handy to capture any fuel that may spill from the carburetors, as fuel is highly flammable and can be ignited by a dryer pilot light etc. from a long distance. Clean up any spilled fuel immediately and dispose of away from any source of ignition. Store the fuel tank in a well vented area, outdoors is best, in the event your fuel taps should leak. Step 4. Remove the rocker boxes by slacking the 9 head bolts a little at a time in a star pattern. Remove the 6 nuts at the front and back of the head. Remove the 4 corner rocker box bolts. Remove the head bolts and rocker boxes. Remove the push rods. Examine the push rods to insure they are straight and the ends are tight. Replace any suspect push rod. Step 5. Remove the cylinder head. Now would be a good time for guide and valve renewal. This is best left to an expert. More cylinder heads have been ruined by auto machine shops than by hard use. If you do not have a qualified shop in your area please call for a referral. Step 6. Remove the push rod tubes and the cylinder base nuts. Clip rubber bands around the top of the lifters to keep them from dropping into the crankcase. Have a few lint free rags handy. Bring the pistons to the top of the stroke and begin lifting off the cylinder. If the cylinder is hard to lift off, thread a nut on one of the base studs and use a tire lever to pry against the bottom fin close to its base using the stud as a fulcrum. After partially raising the cylinder stuff the crankcase mouth with rags to keep any carbon or broken rings from entering the crankcase. These will remain in place until step 12. Step 7. Leaving the rags in the crankcase remove the wrist pin circlips from the pistons and discard. Heat the piston and gently push the wrist pin out. Do not use force as this can damage the connecting rod or its bearings. Be sure to account for all the clips as one left in the crankcase can do extensive damage. Step 8. Clean all gasket surfaces to remove any traces of the old gaskets. Use Pennatex gasket remover if needed. Be very careful not to scratch the gasket surface or to allow any gasket particles to enter the crankcase. Even a small bit of gasket can stop the oil pump from working! Step 9. Note the direction and location of the lifters. These must be replaced in the same position as when removed. Remove the lifter blocks from the old cylinder. Start by removing the small retaining bolts and washers. The lifter blocks are extremely fragile and are easily broken. They are also very expensive so great care must be taken in this step! Triumph special tool 222-616008 is advisable here. Apply pressure to the center of the block only. Do not press against the tangs that locate the lifter! A tool can be fabricated using two dowels to locate in the lifter holes. Step 10. Clean and examine the lifters and camshaft faces. Clean the lifter blocks and remove the sealing oring under the locating flange. Replace these with the new orings in the gasket set. Apply a smear of gasket sealant to the lifter block oring and press into the new cylinder. Be sure the lifter block is parallel with the bores and the grooved block is on the exhaust side. Apply a small amount of assembly oil to the lifters and replace in the exact position they came from

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Dazon Raider Classic 150 (Oil-cooled & Internal Gearbox): Service Manual (single/ double-seat)

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Filed Under (Dazon) by admin on 30-11-2010

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1.2.1 Fuel Please use the gasoline of SAE 90# or above. Also we recommend you to use the unleaded gasoline. 1.2.2 Engine Oil Please use the high-quality engine oil of SAE 10w/30SF. 1.3 Break-in Procedure For your first 2 hours of riding, don’t exceed 2/3 throttles. Vary the engine speed for the first 5 hours. Never hold the engine at full throttle for long periods of time. Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 5 1.4 Specifications DIMENSIONS SINGLE-SEAT / DOUBLE-SEAT Overall Length 2330mm / 2300mm Overall Width 1310mm / 1460mm Overall Height 1425mm / 1425mm Wheelbase 1475mm / 1520mm Ground Clearance 200mm VIN Accord with GMVR A01-01 Statutory Plate& Safety Labels Accord with GB 7258-1997 ENGINE Model DZ1P57QMJ Type Oil-cooled, single cylinder, 4-Stroke Engine Capacity 150cc Displacement 149.6ml Bore X Stroke 57.4mm X 57.8mm Max Power 7.0kw or 7000r/m Max Torque 10.0N.m or 6500 r/m Idle Speed 1700 ± 100 r/m CO Emission 7.0g/km HC Emission 1.0g/km Fuel Type SAE 90# or above (unleaded) Lubricate Oil Type SAE 10W/30SF Lubrication Force & Splash Cooling Oil-cooled Ignition C. D. I. Starting Electric Spark Plug C7HSA (NGK) Spark Plug Gap 0.6~0.7mm Transmission Chain Transmission Gearbox Transmission Ratio F.:7.8:1 ; B.:11.297:1 Compression Ratio 9.5 ± 0.1 : 1 Carburetor MIKUNI BS 24-1005 Absorber Normal (in 10 5 times of experiments) CAPACITIES Front/ Rear Tire Load Coefficient 36 Front/ Rear Tire Speed Level L Fuel Tank 7.0L, 130kpa (no leakage in experiments) Engine Oil 1000ml Gear Oil 200ml Starting Time ≤15s Climbing ≥20%

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HARLEY DAVIDSON XLH 1200cc BIG BORE KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 06-03-2011

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Boring and Honing Procedures 1. Check again for burrs on cylinder gasket surfaces and remove burrs before performing Step 2. 2. Install original head and base gaskets, CYLINDER TORQUE PLATES (Part Number 33446-A) and TORQUE BOLTS (Part Number 33446-4). Tighten TORQUE BOLTS following tightening procedure given in the INSTALLATION, CYLINDER HEAD procedure in the ENGINE section of the Service Manual. NOTE Torque plates, properly tightened and installed with gaskets, simulate engine operating conditions. Measurements will vary as much as 0.001 inch without torque plate. 3. The cylinder must be bored with gaskets and torque plates attached. Bore the cylinder to 0.003 inch under the desired finish size. 1 WARNING CAUTION CAUTION 1 WARNING Kit Number 4. Hone the cylinder to its finished size (See Figure 1) using a 280 grit rigid hone followed by a 240 grit flexible ball hone. Honing must be done with torque plates attached. All honing must be done from the bottom (crankcase) end of the cylinder. Work for a 60 degree crosshatch pattern. 5. See Figure 1. After machining and honing, chamfer the bottom edge of the cylinder liner. the chamfer provides a beveled surface for easier installation of the cylinder over the piston rings. Break leading edge of liner to a flat surface. The bottom edge of the liner will be somewhat sharp after machining. This sharp edge could easily be damaged during installation of the cylinder. Piston Installation The 1200cc pistons have an arrow on the top of the piston. This arrow must face the front of the engine when piston is installed. There is no front cylinder piston or rear cylinder piston. New pistons can be installed in either cylinder. Check piston rings for proper side clearance and end gap (See XLH Service Manual). Be sure end gaps of adjacent rings are installed 90 degrees apart. Assembly Follow assembly and torque specifications given in the ENGINE section of the applicable Service Manual. Replace original gaskets, O-rings and seals with new components furnished in kit. NOTE Push rod covers on 1991 and later models are one-piece and the correct O-rings are as follows: Bottom – Part Number 17944-89 Upper – Part Number 11190 Engine Break In For the first 500 miles, to wear-in critical parts, observe these few simple driving rules: During the first 50 miles, keep the engine speed below 2500 RPM in any gear. Up to 500 miles, vary the engine speed, avoiding any steady speed for long distances. Engine speed up to 3000 RPM is permissible in any gear. Avoid fast starts at wide open throttle. Drive slowly until engine warms up. Avoid running the engine at extremely low RPM in higher gears. 2 of 3 -J00001 1200cc CYLINDER FINAL BORE SIZE AFTER HONING STANDARD BORE DIAMETER 3.4980 inch + 0.0002 inch Figure 1. Bottom Edge of Cylinder Liner Chamfer i04852 Break Edge to Flat Surface

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Aprilia Big Bore Kit 102mm Mounting And Installation instructions

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Filed Under (Aprilia) by admin on 26-10-2010

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The installation takes place as usual. Change the cylinder and pistons. The engine must be brought in at least 500 Km!! Naturally the mapping must be adapted for this conversion! Use a Power Commander or a Rapid Bike Modul and adjust it correctly on a Dyno Stand. The compression ratio is as standard, 12,5:1, like a stock bike! Therefore it is not 100% necessary to change the spark plugs thermal value or the octan value. But if you use your bike for racing then you should go for different spark plugs (we use NGK DCPR9EVX spark plugs) and 98 octan fuel. For best performance use our Racing air filter system (models till my 2003 item # a123, a124, a125. For models up from my 2004 item # a121a). This systems increases the air flow which is a very good effect on all Aprilia models and particularly together with the Big Bore Kit

XR/ CRF100 120 BIG BORE KIT INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 14-11-2011

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Installation of this bore kit is identical to OEM installation. Please re- fer to the Honda shop manual or a qualified machanic for assistance. Note that the larger valve relief in the piston dome is the intake side (it should be installed closer to the rear of the bike). Every effort has been made to insure the quality of this product. Because BBR cannot control the installation or use there is NO
warranty or guarantee with this product. Using quality motor- cycle oil will help prolong engine life. Be sure to change it often.

HONDA XR/ CRF100 120 BIG BORE KIT INSTALLATION AND REMOVAL INSTRUCTIONS

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Filed Under (Honda) by admin on 15-11-2011

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nstallation of this bore kit is identical to OEM installation. Please re- fer to the Honda shop manual or a qualified machanic for assistance. Note that the larger valve relief in the piston dome is the intake side (it should be installed closer to the rear of the bike). Every effort has been made to insure the quality of this product. Because BBR cannot control the installation or use there is NO warranty or guarantee with this product. Using quality motor- cycle oil will help prolong engine life. Be sure to change it often This kit is intended for use on 1993 and newer XR/CRF100′s using CDI ignition. Engine assembly requires special attention to detail. A new BBR Cylinder and piston kit have been supplied. The following measurments are critical to proper installation and performance

Kawasaki KZ 900/ KZ 1000 Piston Kits Installation Manual

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Filed Under (Kawasaki) by admin on 25-10-2010

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075CC 72MM KZ 900: Resleeving and bore crankcase ROAD 10.5:1 MTC-K1075 KZ 1000: 2mm oversize 2.834 In KZ 1000: Cylinder boring DRAG 12.5:1 MTC-K1075H TURBO 9.0:1 MTC-K1075T 1135CC 74MM Resleeving and bore crankcase ROAD 10.5:1 MTC-K1135 KZ 1000: 4mm oversize 2.913 In DRAG 12.5:1 MTC-K1135H TURBO 7.8:1 MTC-K1135T 1197CC 76MM Resleeving and bore crankcase ROAD 10.5:1 MTC-K1197 KZ 1000: 6 mm oversize 2.992 In DRAG 12.5:1 MTC-K1197H TURBO 7.8:1 MTC-K1197T 1261CC 78MM Resleeving and bore crankcase ROAD 10.5:1 MTC-K1261 KZ 1000: 8mm oversize 3.070 In DRAG 12.5:1 MTC-K1261H TURBO 7.8:1 MTC-K1261T 1327CC 80MM Big block required bore crankcase ROAD 10.5:1 MTC-K1327 KZ 1000: 10mm oversize 3.149 In DRAG 13.5:1 MTC-K1327H TURBO 7.8:1 MTC-K1327T 1428CC 83MM Big block required bore crankcase ROAD 10.5:1 MTC-K1428 KZ 1000: 13mm oversize 3.267 In DRAG 13.5:1 MTC-K1428H TURBO 7.8:1 MTC-K1428T 1500CC 85MM Big block required bore crankcase DRAG 13.5:1 MTC-K1500H KZ 1000: 15mm oversize 3.346 In TURBO 7.8:1 MTC-K1500T

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AJS Big-end replacement instructions

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Filed Under (AJS) by admin on 31-10-2010

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Above: Once the first wheel is off, the pin can be removed in the vice using a drift and spacer. Right: Out with the old; in with the new. Big-end track renewal is a two- in-one operation. Left: No wonder the original bearing was making let-me-out noises! New big end assemblies come dipped in a protective plastic coating. Below: A smear of grease stops the new rollers squirting all over the place. Cotton tape holds them tight to the pin, until the big end is in position. Below. Ensure that the new pin is absolutely square before you attempt to press it in. Mating faces must be operating theatre clean. one out of the con-rod as you fit it. A short piece of square-ended pipe makes a spacer, but take great care that the track goes in square. Soft jaws in the vice prevent damage. The new bearing will usually be grease packed, which helps to stick uncaged rollers onto the inner track. Wrap a length of tape around, pulling it out as you drop the big end eye over. Get the rod the right way round! Check the fit, because the con-rod can occasionally squeeze a new outer race so that it nips the rollers. Lapping it in is the cure, but that’s not within the scope of this article. (Universal journalists’ copout). Press up the second flywheel, using a set square to get the alignment about right, and nip up the nut. The scrap box supplied materials for my truing jig. Two pairs of small roller bearings support the mainshafts, and one support post is adjustable to allow for different crank widths and shaft diameters. For ease and accuracy, a dial gauge wins every time, and if you compare it to the cost of employing an expert, you’ll have no difficulty in justifying the expense. Wedge the con-rod between

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