Quad 110 napraa silnikla opisy.pdf

CRF/XR50

106cc Stroker Crank Kit

Thanks for purchasing this

exciting new product from BBR

Motorsports! Extensive R&D

has gone into this product and

we are certain that you will be

just as excited about it as we

are. If you have any questions

please give us a call. Thanks!

Installation Instructions:

Tools Required:

· Honda Service Manual

· 8mm socket, wrench, or T-handle wrench

· 9mm wrench

· 10mm socket, wrench, or T-handle wrench

· Torque wrench

· Special clutch removal wrench (see text)

· Feeler gauges (to adjust the valves)

1028 4th St. SW - A

Auburn, WA 98001

1-888-668-6227

Disclaimer: This big bore kit requires professional instalation. It is

up to you to determine if you have the skls necessary to instal this

kit. If you are not conident in your abilities, please contact a profes-

sional mechanic. This kit instals exactly ike the OEM Honda compo-

nents with the exceptions noted here. You should refer to the OEM

Honda Service Manual for any questions regarding disassembly or

reassembly of your motorcycle engine. Because BBR Motorsports,

Inc. cannot control the assembly of this engine kit, no guarantees

are made as to performance, reliability, or usability. It is entirely up

to the individual doing the installation to determine the itness of this

product and its usabity. Al iabities are the responsibity of this

individual (both consequential and incidental). We recommend using

high quaity motorcycle ol and changing it often.

1. Removal of cylinder head

and cylinder can be done with

the motor in the chassis or re-

moved. Remove throttle cable,

air ilter assembly, carb, drive

chain, skidplate, exhaust sys-

tem, and shift lever.

5. Remove the (4) 10mm nuts

from the top of the cylinder

head cover and remove the

cover.

2. Remove the left side cover

(lywheel cover) by removing

the (3) 6mm bolts (8mm heads).

6. Remove the camshaft

sprocket from inside the left of

the cylinder head by removing

its (2) 6mm bolts (8mm heads).

Remove countershaft sprocket.

3. Remove the left side timing

chain/camshaft cover by remov-

ing the 6mm bolt (10mm head)

on the right side of the engine.

This bolt extends through the

camshaft and secures the cam-

shaft cover.

7. Remove the cylinder head,

gasket, and 2 dowels. Some

force may be required to release

the head gasket. A rubber ham-

mer may be useful. Be careful

not to damage the cylinder or

cylinder head. DO NOT use a

screwdriver to pry the compo-

nents apart or damage will occur.

4. Remove the (3) 6mm bolts

(10mm heads) that hold the

timing chain roller (shown) and

the cylinder head to the cylinder

and the cylinder to the engine

cases.

8. Remove the cam-chain

roller from inside the cylinder by

removing the 6mm bolt (10mm

head). Needle nose pliers may

be helpful to remove the roller

from inside the cylinder.

9. Remove the cylinder from

the engine cases. The base

gasket may also be dificult to

release. Again, a rubber ham-

mer can be used with care.

13. Remove “oil-through-tube”

(this is the name of the part)

and spring. Remove the clutch

lifter cam plate.

Oil - Through - Tube

10. Remove one of the small

piston clips from inside the pis-

ton (use a small screwdriver or

needle-nose pliers). Push out

the piston pin, and remove the

piston from the rod. Use care

not to drop the clip into the en-

gine cases. Place a rag in the

engine openings to prevent this.

14. Remove the (4) Phillips

head screws and then remove

the clutch outer cover.

11. Remove kickstarter le-

ver, brake pedal, and footpeg

mount. Remove clutch cover

(right crankcase cover) by re-

moving the (8) 6mm bolts (8mm

head).

15. Straighten the tab of the

clutch lock nut lock washer.

Remove the clutch lock nut with

the appropriate special clutch

tool. It is available from Honda

as part #07716-0020100.

12. Remove the ball retainer

and spring. Remove the clutch

lifter lever.

Ball Retainer

16. Remove the oil pump by

removing the (3) Phillips head

screws.

Clutch

Lifter

Lever

17. Remove ignition stator base

(2 phillips head screws).

21. Remove the shiftdrum stop-

per arm and camplate (1 bolt

each)

18. Remove camchain tensioner

and cam chain.

22. Remove the snap ring from

the kickstarter shaft, disconnect

the return spring, and slide off the

retainer.

19. Remove the snap ring retain-

ing the driven gear and remove

gear.

23. Remove the shift shaft.

20. Remove primary gear, bush-

ing and spacer. These parts will

need to be installed on your new

crank.

24. Loosen and remove the

crankcase bolts (7).

25. Place the engine left side

down on supports (old 2 X 4’s

work well). Separate the right

and left crankcase halves. May

help to tap transmission shaft

and crankshaft with rubber

hammer.

29. The oil passage for the new

high low oil pump needs to

be drilled to a larger hole size.

Begin by removing the lower left

stud. You can use two of the

cylinder nuts (locked against

each other) to unthread the stud

from the cases. With the stud

removed, use the supplied 2mm

drill bit to drill out the oil pas-

sage. Be very careful to protect

the internal areas of the engine

from stray metal chips when drill-

ing. Be certain to clean up all metal chips before reassembly.

Reinstall the head stud removed above. Install the centercase

gasket and install the right crankcase half over the crankcase.

26. Remove the crank.

27. Clean the crankcase mating

surfaces before assembling.

30. Install the 7 bolts that hold

the crankcase halfs together.

Tighten in a crisscross patern.

28. Install BBR crank into left

crankcase.

31. Install the kickstart shaft with

spring into the right side of the

motor.

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