ULTRA-SE 4 VALVE BIG BORE KIT / VERSION UPGRADE KIT
DISPLACEMENT : (BORE) x (STROKE)
NO.
125cc : I.D. 60 x 44.2mm
143cc : I.D. 60 x 50.6mm
160cc : I.D. 60 x 56.0mm
ATTENTIONS WHEN USING ULTRA SE4V BIG BORE KIT
NO.1/6
VERSION UPGRADE KIT
NO.
ULTRA SE 143cc ⇒ 4 VALVE 143cc
ULTRA SE 143cc ⇒ 4 VALVE 160cc
216-4021930
▼ Reinforce clutch, change to high gear and install oil cooler when installing big bore kit.
215-4021930
215-4021940
SUPER OIL COOLER KIT (KSR110)
SUPER OIL COOLER KIT (KLX110)
MANUAL CLUTCH KIT
MANUAL CLUTCH KIT (with HIGH GEARED CLUTCH OUTER KIT)
REINFORCED CLUTCH SPRING SET
HIGH GEARED CLUTCH OUTER KIT
OIL COOLER KIT
(for each model)
215-4021920
216-4021940
KSR110 FNo.KL110A-A02833 〜（MODEL CODE：KL110-A2 〜）
APPLICATION
KLX110 FNo.LX110A-A08133 〜（MODEL CODE：KLX110-A2 〜）
REMARKS
Some models may require case boring due to KAWASAKI stock error.
CLUTCH
OPTION PARTS (Purchase if necessary.)
● Read and understand the instruction before installing.
● There are special tools required to install this kit.
● Use this instruction for setting manual afterwards.
※ Keep this instruction since it is not included in repair parts.
■ ATTENTIONS (MUST READ)
● Race use only. Note that racing parts are not covered under warranty.
● We are not responsible for damages and accidents caused by assembling mistake and improper setting.
● Change spark plug and gears and make the right setting when installing.
Change the clutch springs to reinforced ones.
Use KITACO carburetor and muffler. Do not use other manufacturer parts since it may cause trouble.
Make sure to make the right setting suitable for engine.
If running without the right setting, you cannot improve and may cause seizure and damage.
● Follow the instructions and install correctly. Do not modify the way which is not listed, or it will cause damage and trouble.
● Ask a mechanic or a specialist at a specialty shop for assembling and setting if you do not understand the role of the surrounding parts.
● Change the engine oil to the new specified one after you break-in (about 100km).
▼ R CRANKCASE COVER GASKET (unnecessary when installing with KITACO MANUAL CLUTCH KIT)
and liquid gasket are required when installing 125/160cc KIT.
R CRANKCASE COVER GASKET
LIQUID GASKET TB1207B
GASKETS
966-4021002
969-0500200
▼ Basic tools and other special tools are required when installing crankshaft included in 125/160cc KIT.
KAWASAKI SPECIAL TOOLS
KITACO TOOL
CRANKSHAFT JIG
FLYWHEEL HOLDER
KAWASAKI BOND (SILICONE SEALANT)
FLYWHEEL PULLER
KAWASAKI : 57001-1174
KAWASAKI : 57001-1313
KAWASAKI : 56019-120
674-0500120
▼ Change intake parts when installing this big bore kit.
CARBURETOR
KITACO Specified Oil: elf xt3818 [5W-30] (1L : 968-2000010) elf MOTO4 PRO TECH [5W-40] (1L : 968-2000021)
● Refer to the KAWASAKI service manual for each vehicle when installing.
● Bolts and nuts may get loosen by engine vibration. Make sure to check that each part of bolts and nuts are not loose before
running.
● Clean each parts by parts cleaner and use air duster to check whether the oil line is choked up.
● Oil the parts with engine oil when assembling.
● Do not use rapid engine brake. For kick starting, make sure to kick the pedal after you check the gear is engaged.
● Make sure to run under 9,000rpm when break-in.
330-4021100
330-4022100
307-4021700
307-4021800
307-4021600
307-4021770
CDI (for each model)
KSR110 MIKUNI VM26 (for SE cylinder head)
KLX110 MIKUNI VM26 (for SE cylinder head)
KLX110 KEIHIN PWK28 (for SE cylinder head)
KSR110 KEIHIN PWK28 (backwards type)
KLX110 KEIHIN PWK28 (backwards type)
STAINLESS UP MUFFLER (KSR110)
HIGH END DOWN MUFFLER (KSR110)
STAINLESS UP MUFFLER RIGHT SIDE PIPE (KLX110)
STAINLESS UP MUFFLER LEFT SIDE PIPE (KLX110)
POWER REV2 (KSR110)
POWER REV2 (KLX110)
110-4021013
110-4022013
110-4022128
110-4021128
110-4022228
540-4021100
540-4021720
540-4022610
540-4022620
766-4021300
766-4022300
ATTENTIONS WHEN INSTALLING
CRANKCASE BORING
● Make sure to check if there is (more than 0.3〜0.5mm)
clearance between cylinder sleeve and crankcase.
Bore the case if clearance is under 0.3mm or if sleeve does
not fit the case.
※ There are some models which modification is unnecessary.
FLAMMABLES
Inflammable high
gasoline is used
during operation.
The use of products
causing fire or smoke
is strictly prohibited.
It is recommended to follow the chart
and inspect and change regularly to
keep the best performance.
※ On a harsh operating condition, we
recommend to inspect and change
earlier than the listed maintenance
cycle.
Especially change piston, rings, pin
and clips every race.
EXTREMELY HOT
Do not touch the
engine parts (cylinder,
crankcase, muffler,
engine oil, etc...) right
after enigne operation.
Make sure to start
the installation after
the engine parts are
completely cool.
TOXIC
Toxic, highly-volatile
gasoline is used
during operating.
Make sure to ventilate
the room and do not
operate for hours in
a hermetically closed
room.
HIGH VOLTAGE
Wear insulated glove
when checking the
sparking outside the
cylinder.
PERIODIC MAINTENANCE CHART
CRANKCASE
CYLINDER
CYLINDER HEAD
PISTON
PISTON RING
PISTON PIN
PISTON PIN CLIP
CRANKSHAFT
EVERY 1 RACE (2 HOURS)
Inspect, clean
Inspect, clean, modify
Inspect, clean, adjust, modify
Inspect, clean
Inspect, clean
Inspect, clean, modify
Change
Inspect, clean, modify
CRANKCASE BORING PART
REMARKS
Change if necessary.
Change if I.D. is over 60.060mm.
Refer to No.6 service guide.
Change every 500km. ※
Change every 500km. ※
Change every 500km. ※
Refer to No.6 service guide.
RIGHT SIDE CRANKCASE
This sheet is for
the person who has
basic knowledge for
maintenance. Do not
operate if you do
not have skill and
knowledge.
TOP VIEW
MAKE SURE THE CLEARANCE
BETWEEN SLEEVE AND CRANKCASE HAVE MORE THAN 0.5mm
INSTALLATION OF 160cc
(INTERFERENCE OF CRANKSHAFT)
● Modify both side of crankcase where the 160cc
crankshaft connecting rod interferes.
INSIDE CRANKCASE
※ Clean and remove the
shavings completely
after modification.
MUST MODIFY HERE
SLEEVE
LEFT SIDE CRANKCASE
MODIFY BOTH SIDE OF
CRANKCASE WHERE IT
INTERFERES
CLEAN THE OIL PATH
BY COMPRESSED AIR
R
BORE 20mm DEPTH
R : BORE THE EDGE SMOOTH
※ Do not shave too much and make sure to stuff some cloth into the crankcase hole not to let the shaves go into it.
※ Restuff some clean cloth to keep the crankcase hole out of foreign object during installation.
※ Ask a specialist to modify if you do not have machine or skills to modify.
ULTRA-SE 4 VALVE BIG BORE KIT / VERSION UPGRADE KIT
■ CYLINDER HEAD PARTS
(The engine illustration is KSR110's)
Refer to No.5
B3
B4
B2
Refer to No.4
CODE
A
B1
B2
B3
B4
C1
C2
C3
C4
C5
C6
C7
D
D1
D2
A
N2
B1
N3
Refer to No.4
order of tightening
D3
N5
Refer to No.5
N8
N6
N14
N17
N18
C1
C2
D6
Refer to No.5
N15
N16
N7
Refer to No.5
N4
D4
C7
D6
Refer to No.5
C5
N12
C4
N12
D1
D2
D3
D4
D5
D6
D7
E1
E2
F1
F2
F3
F4
C6
N13
N22
Refer to No.4
order of tightening
→ Refer to instructions of other page.
→ Refer to list's remarks column.
→ Apply engine oil.
▼ CRANKCASE is listed in No.3.
160cc
BIG BORE KIT
143cc
VERSION
UPGRADE KIT
216-4021930
×1
OP
NAME
NO.
215-4021920
215-4021930
215-4021940
ULTRA-SE 4V CYLINDER HEAD ASSY
313-4021900
×1
×1
×1
SILENT CAM CHAIN (SV94)
299-4021094
×1
×1
×1
DENSO IRIDIUM SPARK PLUG IY24
025-015-0240000
×1
×1
×1
PLUG CAP 70-B
751-0500110
×1
×1
×1
PLUG WRENCH 13mm
674-0400900
×1
×1
×1
PLATED CYLINDER I.D. 60mm
311-4021710
×1
×1
×1
FORGED PISTON I.D. 60mm (for 4V 125cc) 3R (0.8 x 0.8 x 1.5) 351-4021920
×1
FORGED PISTON I.D. 60mm (for 4V 143cc) 3R (0.8 x 0.8 x 1.5) 351-4021930
×1
FORGED PISTON I.D. 60mm (for 4V 160cc) 3R (0.8 x 0.8 x 1.5) 351-4021940
×1
PISTON RING I.D. 60mm 3R (0.8 x 0.8 x 1.5)
352-4021100
×1
×1
×1
PISTON PIN 13 x 40
353-0001340
×1
PISTON PIN 14 x 40 (CrN type)
353-2001440
×1
×1
GASKET SET-A (for 143cc)
960-4021100
×1
GASKET SET-A (for 125/160cc)
960-4021200
×1
×1
HEAD GASKET I.D. 60mm
961-4021100
（× 1）
（× 1）
（× 1）
MANIFOLD GASKET
950-1015000
（× 1）
（× 1）
（× 1）
EX GASKET (XK-12)
963-4021000
（× 1）
（× 1）
（× 1）
BASE GASKET
962-4021000
（× 1）
（× 1）
（× 1）
PISTON PIN CLIP 13mm
354-0000130
（× 2）
PISTON PIN CLIP 14mm
354-0000140
（× 2）
（× 2）
L CRANKCASE GASKET
966-4021001
（× 1）
（× 1）
（× 1）
SHORT STROKE CRANKSHAFT ASSY 44.2mm
309-4021000
×1
LONG STROKE CRANKSHAFT ASSY 56mm
309-4022000
×1
R CRANKCASE COVER GASKET
966-4021002
OP
OP
OP
MANUAL CLUTCH KIT
307-4021700
OP
OP
OP
REINFORCED CLUTCH SPRING SET
307-4021600
OP (USE 4 PCS) OP (USE 4 PCS) OP (USE 6 PCS) OP
HIGH GEARED CLUTCH OUTER KIT
307-4021770
OP
OP
OP
160cc
VERSION
UPGRADE KIT
216-4021940
×1
OP
×1
×1
×1
×1
×1
×1
×1
（× 1）
（× 1）
（× 1）
（× 1）
（× 2）
（× 1）
×1
（× 1）
（× 1）
（× 1）
（× 1）
（× 2）
（× 1）
×1
OP
OP
OP
OP
(USE 4 PCS) OP (USE 6 PCS)
OP
OP
▼ STOCK PARTS (REMARKS/TORQUE)
D5
N19
N11 N10
N9 N10
※NEW
※NEW
143cc
BIG BORE KIT
▲ OP mark means OPTION. Purchase if necessary.
C3
D5
※
125cc
BIG BORE KIT
ULTRA-SE 4 VALVE PACKING LIST
※NEW
※NEW
N9 N10 N11 N10
N1
NO.2/6
※ Reuse stock parts that are not included in the kit.
Change the reusing parts with new ones if there are significant blem, fatigue or wear.
N22
N21
N20
N19
CODE
N1
N2
N3
N4
N5
N6
N7
N8
N9
N10
N11
N12
N13
N14
N15
N16
N17
N18
N19
N20
N21
N22
NAME
M8 CAP NUT
8mm FLAT WASHER
M6 x 106 BOLT
M6 FLANGE NUT
STUD BOLT
M6 x 20 BOLT
M6 x 12 CAP BOLT
CAM SPROCKET
M8 x 20 BANJO BOLT
8mm SEALING WASHER
OIL PIPE
DOWEL PIN 8.2 x 10 x 14
CAM CHAIN GUIDE
M6 x 25 HEX FLANGE BOLT
CAM CHAIN TENSIONER
O RING 21mm
TENSIONER BOLT
O RING
M6 x 25 PAN HEAD SCREW
M6 x 45 PAN HEAD SCREW
L CRANKCASE COVER
DOWEL PIN 6.2 x 8 x 14
PCS
×4
×1
×2
×2
×2
×4
×2
×1
×2
×4
×1
×4
×1
×2
×1
×1
×1
×1
×6
×3
×1
×2
TORQUE
22N・ｍ（2.2kgf・m）
12N・ｍ（1.2kgf・m）
12N・ｍ（1.2kgf・m）
14N・ｍ（1.4kgf・m）
5.2N・ｍ（0.53kgf・m）
12N・ｍ（1.2kgf・m）
REMARKS
Refer to No.4 order of tightening
(Does not include in some models)
Refer to No.4 order of tightening
15N・ｍ（1.5kgf・m）
Change to new one (KITACO NO. 092-0501008 / KAWASAKI NO. 11009-1344)
5.2N・ｍ（0.53kgf・m）
5.2N・ｍ（0.53kgf・m）
5.2N・ｍ（0.53kgf・m） Apply KAWASAKI BOND (SILICONE SEALANT)
5.2N・ｍ（0.53kgf・m） Apply KAWASAKI BOND (SILICONE SEALANT)
ULTRA-SE 4 VALVE BIG BORE KIT / VERSION UPGRADE KIT
■ CRANKCASE PARTS(The engine illustration is KSR110's)
NO.3/6
▼ STOCK PARTS (REMARKS/TORQUE)
F2
→ Refer to instructions of other page.
※
→ Refer to list's remarks column.
→ Apply engine oil.
N33
N34
Refer to No.4
N74 order of tightening
F1
F2
N74
N73
N32
N31
N74
N44
N70
N71
N72
N43
F4
N56 ※ Apply
locking agent ※ Apply locking
agent right here
N69
N41
N40
N41
※ Check the number of spring
Refer to No.2
Refer to No.4
※ Apply liquid gasket
N67
N48
N39
※ Apply
locking agent N53 N48
N52
N51
N50
N61
E1
N68
N64
N66
N48
N65
N45
Use special tool to
press fit crankshaft
N49
N60
N62
N48
E2
N48
N63
F4
N58
N45
F2
N57
N55
N41
N40
N40
N36
N59
N56
N73
N40
N37
N35
N73
N42
※ Check the number of screw
Refer to No.2
TORQUE
N38
（0.35kgf・m） F3
3.4N・m
F3
N73
N38
N54
N48
F2
N78
N49
N47
N45
N45
N46
Refer to No.4
order of tightening
N75
N76
N77
N48
D7
※ Use special tool to remove
Refer to No.5
CODE
N31
N32
N33
N34
N35
N36
N37
N38
N39
N40
N41
N42
N43
N44
N45
N46
N47
N48
N49
N50
N51
N52
N53
N54
N55
N56
N57
N58
N59
N60
N61
N62
N63
N64
N65
N66
N67
N68
N69
N70
N71
N72
N73
N74
N75
N76
N77
N78
NAME
M6 x 35 PAN HEAD SCREW
R CRANKCASE COVER ASSY
FILLER CAP
O RING 31.7 x 2.4
BEARING
BEARING HOLDER
CLUTCH LIFTER PLATE
M14 NUT
CLUTCH CENTER
CLUTCH DISK
FRICTION PLATE
CLUTCH PRESSURE PLATE
COLLAR 17 x 22 x 22.7
SPACER
M6 x 25 PAN HEAD SCREW
M6 x 30 PAN HEAD SCREW
OIL PUMP ASSY
DOWEL PIN 6.2 x 8 x 14
O RING 10mm
M6 x 30 CAP BOLT
HOLDER
SHIFT DRUM CAM
PIN 4 x 8
SHIFT SPINDLE ASSY
M6 x 14 PAN HEAD SCREW
M6 x 14 HEX BOLT
POSITION PLATE
SHIFT STOPPER ARM SPRING
SHIFT STOPPER ARM
STOPPER ARM SPACER
KICK STARTER SPRING
KICK STARTER SPRING GUIDE
OIL STRAINER
R CRANKCASE ASSY
DRAIN BOLT M12 x 15
SEALING WASHER 12mm
L CRANKCASE ASSY
WOODRUFF KEY
CAM CHAIN GUIDE
M6 x 25 HEX FLANGE BOLT
CAM CHAIN TENSIONER GUIDE
COLLAR
M6 x 75 PAN HEAD SCREW
M6 x 50 PAN HEAD SCREW
M12 NUT
FLYWHEEL
GENERATOR COVER ASSY
M6 x 45 PAN HEAD SCREW
PCS
×9
×1
×1
×1
×1
×1
×1
×2
×1
×4
×3
×1
×1
×1
×8
×1
×1
×7
×4
×1
×1
×1
×1
×1
×3
×1
×1
×1
×1
×1
×1
×1
×1
×1
×1
×1
×1
×1
×1
×1
×1
×1
×5
×5
×1
×1
×1
×3
TORQUE
5.2N・ｍ（0.53kgf・m）
REMARKS
72N・ｍ（7.3kgf・m）
5.2N・ｍ（0.53kgf・m）
5.2N・ｍ（0.53kgf・m）
5.2N・ｍ（0.53kgf・m） Apply locking agent
5.2N・ｍ（0.53kgf・m）
5.2N・ｍ（0.53kgf・m） Apply locking agent
29N・ｍ（3.0kgf・m）
Apply liquid gasket TB1207B (refer to No.4)
5.2N・ｍ（0.53kgf・m）
5.2N・ｍ（0.53kgf・m） Apply locking agent (specified part only)
5.2N・ｍ（0.53kgf・m）
54N・ｍ（5.5kgf・m）
www.kitaco.it
5.2N・ｍ（0.53kgf・m） Apply KAWASAKI BOND (SILICONE SEALANT)
ULTRA-SE 4 VALVE BIG BORE KIT / VERSION UPGRADE KIT
NO.4/6
APPLYING LIQUID GASKET
(N67) L CRANKCASE ASSY
(A) CYLINDER HEAD ASSY (No. 313-4021900)
● VALVE PARTS (assembled)
Aa2
TORQUE：5.2N・ｍ
（0.53kgf・m）
※ Tappet shim (Ad) is modified at KITACO and assembled when shipping.
Use HONDA DREAM50 tappet shim when maintenance or adjusting valve
clearance.
※ Installing and removing tappet shim
Make sure that the cam is at TDC.
Remove cam sprocket, stopper plate and rocker arm shaft.
Then you will be able to remove or install tappet shim.
Aa3
Aa4
Aa8
CAUTION! :Do not apply to the dotted line part.
ORDER OF TIGHTENING CRANKCASE SCREW
Ad
Ac3
※ Apply locking agent to (N73) M6 x 75 PAN HEAD SCREW.
Ac4
Ac5
Aa1
Aa4
Aa3
Ac6
（N74） （N74）
Ac7
③
Ac1
※ Be aware of valve spring's installing direction.
The blue mark is top (retainer side).
Aa7
④
②
（N73）
⑤
（N74）
Aa6
Aa9
Aa5
Ac7
（0.53kgf・m）
TORQUE：5.2N・ｍ
Ad
Ac3
(A) ORDER OF TIGHTENING
CYLINDER HEAD BOLT
MANIFOLD MOUNTING POSITION
MIKUNI VM26
KEIHIN PWK28
N1
②
④
FWD
③
FWD
①
⑤
▲ TORQUE
NAME
⑨
Ac4
（N73）
Ac5
→ Refer to instructions of other page.
※
→ Refer to list's remarks column.
→ Apply engine oil.
Ab
N3
Ac2
Ac6
Ab1
CODE
（N74）
（N73）
Aa8
⑥
⑥
※⑩
Aa2
PCS
N1
M8 CAP NUT
×4
N3
M6 x 106 BOLT
×2
TEMPORARY TORQUE
13N・ｍ（1.3kgf・m）
5.9N・ｍ（0.6kgf・m）
FINAL TORQUE
22N・ｍ（2.2kgf・m）
12N・ｍ（1.2kgf・m）
CODE
Aa1
Aa2
Aa3
Aa4
Aa5
Aa6
Aa7
Aa8
Aa9
Ab
Ab1
Ac1
Ac2
Ac3
Ac4
Ac5
Ac6
Ac7
Ad
NAME
ULTRA-SE4V CYLINDER HEAD COMP
CAP BOLT M5 x15
TAPPET COVER SE4V
TAPPET COVER GASKET SE4V
CAP BOLT M6 x 15
STOPPER PLATE SE4V
CAMSHAFT SE4V
VALVE ROCKER ARM
ROCKER ARM SHAFT SE4V
HEAD SIDE COVER
L SIDE COVER GASKET
SE4V IN VALVE
SE4V EX VALVE
VALVE COTTER
VALVE SPRING RETAINER
VALVE SPRING SE4V
VALVE SPRING SEAT SE4V
VALVE STEM SEAL
TAPPET SHIM 1.200 〜 2.800
HONDA 14901 〜 14965-KT7-013 0.025mm interval
No.
313-4021901
050-0500015
310-4021991
310-4021992
060-0500015
300-4021909
300-4021900
303-4021700
303-4021701
310-4021100
966-4021003
302-4021901
302-4021902
303-1417904
303-1417903
303-4021901
303-4021905
303-1417902
313-4021900
×1
×6
×2
×2
×2
×1
×1
×2
×2
×1
（× 1）
×2
×2
×8
×4
×4
×4
×4
×4
①
⑧
（N74） （N73）
⑦
（N73）
▲ TORQUE (CRANKCASE)
PCS
TORQUE
CODE
NAME
N73
M6 x 75 PAN HEAD SCREW
× 5 5.2N・ｍ（0.53kgf・m）
N74
M6 x 50 PAN HEAD SCREW
× 5 5.2N・ｍ（0.53kgf・m）
ORDER OF TIGHTENING L CRANKCASE COVER SCREW
Apply KAWASAKI BOND (SILICONE SEALANT)
④
（N45）
③
（N45）
②
⑤
（N45）
（N78）
⑨
（N78）
①
⑧
（N78）
（N78）
（N78）
⑥
⑦（N78）
▲ TORQUE (CRANKCASE COVER)
PCS
TORQUE
CODE
NAME
N45
M6 x 25 PAN HEAD SCREW
× 6 5.2N・ｍ（0.53kgf・m）
N78
M6 x 45 PAN HEAD SCREW
× 3 5.2N・ｍ（0.53kgf・m）
ULTRA-SE 4 VALVE BIG BORE KIT / VERSION UPGRADE KIT
NO.5/6
■ ADJUSTMENT AND INSTALLATION
ADJUSTING VALVE TIMING
MARK
5
MARK
4
3
Install the piston rings as it is shown.
※ The mark of TOP RING and SECOND RING
must be set upward.
※ Set ring's disconnected part as it is shown.
※ There is no specified direction of top or bottom
for EXPANDER and SIDE RAIL.
※ The number is the order to install.
2
120°
4. SECOND RING
120°
NO. NAME
PCS
1
×1
EXPANDER
2/3 SIDE RAIL (BOTH SAME)
×2
4
SECOND RING (BLACK)
×1
5
TOP RING (WHITE)
×1
2cm 3. SIDE RAIL
INSTALLING AND REMOVING STUD BOLT
B
C
①WHEN LOOSENING
①
FLYWHEEL
A. Put 2 pcs of M6 size nut to the stud bolt.
B. Use spanner for each nut and tighten.
C. Turn ① counterclockwise when loosening
and turn ② clockwise when tightening.
ADJUSTING VALVE CLEARANCE
○ With correct valve timing, insert the thickness gauge between the rocker arm and
tappet shim and pull it. Check if you feel strong resistance.
It is not correct if you could not pull out or feel any resistance.
VALVE CLEARANCE : 0.15±0.03mm
※ Check intake side and exhaust side (total 4 section).
THICKNESS GAUGE
②WHEN TIGHTENING ②
○VALVE CLEARANCE ADJUSTMENT
1. Make sure the cam is at TDC and insert 0.15mm thick thickness gauge between
rocker arm and tappet shim.
2. Valve clearance is correct if you feel strong resistance when pulling out the
thickness gauge. Adjust if the valve clearance is incorrect. Insert thinner thickness
gauge if 0.15mm thick thickness gauge does not fit in, or insert thicker one if you
do not feel resistance when pulling. Keep measuring the thickness until you feel
strong resistance.
3. Take a note of the thickness when you feel strong resistance.
4. Measure the thickness of tappet shim by micro gauge and calculate the required
thickness of shim. (Refer to No.6 REQUIRED NEW SHIM) Set the new shim,
measure the tappet clearance and make sure the clearance is correct.
※ The thickness is written on the tappet shim but make sure to measure it with
micro gauge to check the accurate thickness.
TIGHTENING SPARK PLUG
WHEN NEW
30°
120°
Tighten the spark plug by torque wrench in 0.9kg/m.
If not using torque wrench, tighten till it touches the plug washer,
then use plug wrench and tighten 120°
when new, 30°
when reusing.
Do not tighten more than it is mentioned because the screw thread may break.
WHEN REUSING
INSTALLING AND REMOVING FLYWHEEL
1
2
FLYWHEEL HOLDER
ADJUSTING CAM CHAIN TENSIONER
PUSH ROD PLATE
9.5mm
1. Fix the flywheel by flywheel holder and remove the center nut.
2. Fix the flywheel puller by spanner and pull out the flywheel by turning the bolt part of flywheel puller.
4
15mm
FLYWHEEL PULLER
6
CENTER NUT
INSTALLATION (VALVE TIMING ADJUSTMENT)
○ Check crankshaft position to see that the "T" mark on the magneto flywheel aligns
with the index mark on the crankcase.
○ Pull the camshaft chain taut before rotating the crankshaft.
○ Pull the lower side of the chain taut and fit it onto the sprocket so that the line "T"
on the sprocket aligns with the sprocket cover mating surface projection.
※ Turn the camshaft so that the cam lobes point downward.
○ Install the camshaft chain tensioner. (Refer to illustration of chain tensioner)
○ Turn the crankshaft two turns in counterclockwise,
when the crankshaft is at TDC, re-check the camshaft chain timing.
(If the timing mark is aligned, the camshaft chain timing is correct.)
CAUTION
Rotation of the crankshaft with improper camshaft timing could cause the valve to
contact each other or the piston, and bend.
If any resistance is felt when turning the crankshaft, stop immediately,
and check the camshaft chain timing.
INDEX MARK
&
T MARK
1. EXPANDER
A
CAUTION
Always pull the camshaft chain taut while turning the crankshaft
when the camshaft chain is loose.
This avoids kinking the chain on the lower (crankshaft) sprocket.
A kinked chain could damage both the chain and the sprocket.
※ Piston's EX mark faces to exhaust side.
120°
2. SIDE RAIL 2cm
INDEX MARK
&
T MARK
PISTON RING
1
5. TOP RING
REMOVAL
○ Turn the crankshaft counterclockwise until the line adjoining the line mark on the
camshaft sprocket (T) aligns the sprocket
cover mating surface projection. (Refer to illustration)
○ Remove the camshaft chain tensioner. (Refer to illustration of chain tensioner)
CAMSHAFT SPROCKET
FT
INSTALLING PISTON RING
CAUTION
This is a non-return type cam chain tensioner.
The push rod does not return to its original position once it moves out to
take up cam chain slack.
Once the bolts are loosened, the tensioner must be removed. Retightening
the mounting bolts from halfway could damage.
Do not turn over the crankshaft while the tensioner is removed.
This could upset the cam chain timing, and damage the valves.
○ While compressing the push rod, turn it clockwise with a suitable screwdriver
until the rod protrusion comes to about 10mm from the tensioner body.
○ While holding the rod in position with a suitable push rod holder plate
install the tensioner on the cylinder block.
Take out the holder plate and tighten the cap bolt after installing the tensioner.
ULTRA-SE 4 VALVE BIG BORE KIT / VERSION UPGRADE KIT
NO.6/6
SERVICE GUIDE inside ( ) is for 143cc
ITEM
CAMSHAFT
VALVE
VALVE GUIDE
VALVE SPRING
PISTON
CYLINDER
CRANKSHAFT
BEARING
STANDARD (mm)
A
CAM LOBE HEIGHT
B
STEM O.D.
C
GUIDE I.D.
-
CLEARANCE OF STEM
AND GUIDE
IN
EX
IN
EX
IN
EX
IN
EX
IN
D
VALVE SEAT WIDTH
E
FREE LENGTH
F
O.D.
G
PIN HOLE
I.D.
H
PISTON PIN
O.D.
EX
IN/EX
I
CLEARANCE OF CYLINDER AND PISTON
J
I.D.
K
CIRCULARITY
L
CYLINDRICALITY
M
N
CONNECTING ROD
LARGE END
O
CONNECTION ROD SMALL END I.D.
P
CRANKSHAFT RUNOUT
Q
R
BEARING IN/OUT
SIDE CLEARANCE
RADIAL CLEARANCE
SIDE CLEARANCE
RADIAL CLEARANCE
CAMSHAFT
VALVE SPRING
VALVE GUIDE
28.95
28.90
28.88
28.80
3.475 〜 3.490
3.470
3.455 〜 3.470
3.445
3.500 〜 3.512
3.532
3.500 〜 3.512
3.552
0.010 〜 0.037
0.062
0.030 〜 0.057
0.107
0.8
1.3
1.0
1.5
34.3
33.0
59.980 〜 59.990
59.95
14.002 〜 14.008（13.002 〜 13.008） 14.015（13.015）
13.994 〜 14.000（12.994 〜 13.000） 13.98（12.98）
0.020 〜 0.050
0.10
60.010 〜 60.030
60.08
−
0.05
−
0.05
0.1 〜 0.35
0.55
0 〜 0.012
0.05
14.016 〜 14.034（13.0）
14.05
−
0.10
0.05 〜 0.09
OVER 0.10
0.005 〜 0.040
OVER 0.050
PISTON PIN
PISTON
VALVE
SERVICE LIMIT (mm)
I
H
F
A
E
C
B
G
D
F
F: Measure 8mm above from
end of piston skirt
CYLINDER
K
K: (gap of x and y)
y L: (x or y, gap of top・center・bottom)
x
J
CRANKSHAFT
Q
N
O
BEARING
P
P
L
Q
R
REQUIRED NEW SHIM
a:
b:
c:
d:
Required new shim thickness
Measured valve clearance
Specified valve clearance (0.15±0.03mm)
Thickness of removed shim
N
M
※ Use HONDA DREAM50 TAPPET SHIM.
HONDA NO. 14901〜14965-KT7-013 (1.200〜2.800 0.025mm interval)
※ Check valve seat when the shim thickness is over 2.800mm.
Remove the accumulated carbon and modify the valve seat.
※ Make sure to check the thickness of new shim with micro gauge.
CALCULATION FORMULA a = ( b - c ) + d
(Example)
When measured valve clearance is 0.25 and the thickness of shim is 1.900
0.25 - 0.15 + 1.900 = 2.000 which means you will use 2.000mm shim
※ REMOVAL AND INSTALLATION OF TAPPET SHIM
Make sure that the cam is at TDC.
Remove cam sprocket, stopper plate and rocker arm shaft.
Then you will be able to remove or install tappet shim.
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080731
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