Honda CRF/ TRX 450R Camshaft Installation

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Filed Under (Honda) by admin on 19-11-2011

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Break-in of this camshaft is important and you should adhere to all of the following instructions. It is also very important to use plenty of engine assembly lubricant, recommended is Coastal Engine Assembly Lube or Clevite 77, both are available from most automotive supply companies. We recommend you change the engine oil before the initial start-up of the engine after the assembly. Then change the oil again after the break-in of the cams to remove the excess
phosphate from the coated cams. These steps will help ensure that the camshaft breaks-in properly and that you have a long lasting product. Using full synthetic engine oil during break-in is not recommended but, is OK to use after the one-hour break-in period is over. Following a regular maintenance schedule is the best way to ensure durability and performance over the long run. Cleanliness is always a good place to start. Make sure the motorcycle is cleaned thoroughly before you start. It would be advisable to use an engine degreaser on the frame and the engine. Remove the fuel tank and thoroughly clean the inside of the frame rails, around the carburetor, and behind the radiators. Be sure to remove the ignition coil assembly and using high-pressure air, clean the spark plug hole out before the plug is removed. This will ensure a clean engine during the assembly process and less of a chance of thread damage and/or dirt contamination in the engine during reassembly

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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

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ENGINE ASSEMBLY MANUAL 450i, ENGINE REPAIR STAND – 450i

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Filed Under (Tips and Review) by admin on 28-11-2010

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INSTALLING THE CLUTCH : æ Install the bronze bushing, the clutch basket, the spacer washer and the clutch hub. Install the conical washer, apply thread locking material to the threads and install the nut. Use tool #R447 to hold the assembly and tighten the nut to 150 Nm . æ Soak the friction discs in engine oil prior to installation. Alternatively install a friction disc followed by a metal disc until they are all installed, the last disc to be installed will be a friction disc. Install the clutch actuating rod, the clutch lifter piece, the needle thrust bearing and the thrust washer. Install the pressure plate, the six springs, the six washers and the six screws. Tighten the screws to 11 Nm . Tool #R447
Page 8 sur 26 æ Install the two locating dowels, install a new gasket, and note that Sherco uses a special gasket with an integrated silicone bead. Do not use gasket sealer on the mating surfaces as the sealer could plug the oil passages. Install the clutch cover and tighten the twelve screws to 11 Nm . o INSTALLING THE CAM CHAIN DRIVE GEAR ON THE LEFT HAND SIDE OF THE CRANKSHAFT: æ Using a thermal heat gun, heat the cam chain drive gear to ≈ 100°C , install the gear on the LH side of the crankshaft after installing the key, install the circlip. Use care to avoid damage to the end of the crankshaft. Page 9 sur 26 o INSTALLATION OF THE CYLINDER : æ Use a sharp chisel to remove any of the metal gasket that protrudes above the cylinder mounting surface.

KAWASAKI KLX 140 160cc BORE KIT INSTALLATION INSTRUCTIONS

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

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Engine assembly requires special attention to detail. Your cylinder must be bored to fit this new piston. For long engine life it is very important that the cylinder bore is professionally machined to be very round and without taper. Piston-to-Cylinder Clearance: .002″ Ring End Gap: .007″ – .012″ Once the cylinder is bored to size, installation of this piston kit is identical to OEM installation. Please refer to the Kawasaki shop manual or a qualified mechanic for assistance.The side of the piston marked EX should go toward the exhaust port. Coat both sides of copper gasket with a quality gasket sealer. (Gasgacinch or comparable product) 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 motorcycle oil will help prolong engine life. Be sure to change it often. Recommended main jet: 100 Main (at sea level, 65 degrees) Recommended Fuel: 91-93 octane pump fuel

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