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TB 88cc Install Instructions Manual

Big bore kit

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88cc Big Bore Kit Install Instructions
Before installing a big bore kit, you should first install a high volume oil pump. A
high volume oil pump will deliver up to 300% more oil to your top end which will
only help preserve the life of your engine. To install the big bore kit you will need
to:
1. Stuff a CLEAN rag behind the piston to seal off the crankcase.
2. Install a c-clip into one side of the piston. When installing the c-clip,
compress the c-clip just enough to get it into the piston. Note the position of
the c-clip once it is installed.
3. Install the thin retaining rings and the wavy oil ring onto the bottom of
groove on the piston. Carefully slide one thin retaining ring on, then the
wavy oil ring, and then the other thin retaining ring. Make sure that the gap
on each ring faces the opposite direction as shown in the picture.
© 2004 Dano's Bike Shop
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Summary of Contents for TB 88cc

  • Page 1 88cc Big Bore Kit Install Instructions Before installing a big bore kit, you should first install a high volume oil pump. A high volume oil pump will deliver up to 300% more oil to your top end which will only help preserve the life of your engine. To install the big bore kit you will need 1.
  • Page 2 4. Install the lower piston ring (which is flat black in color) onto the lower groove in the piston. After the lower ring has been installed, install the upper ring, which is shiny in appearance. Note that the gap opening on each ring faces the opposite direction.
  • Page 3 8. Install the cylinder gasket. 9. Install a small black seal into the lower hole. 10. Install two knock pins. 3 of 8 © 2004 Dano’s Bike Shop...
  • Page 4 11. Apply a small amount of CLEAN oil into the cylinder and slide the cylinder over the studs. Compress the first piston ring with one hand while CAREFULLY sliding the cylinder over the ring. Do not force the cylinder into place. Repeat the process for each ring until the cylinder is in place. 12.
  • Page 5 14. Install the new camshaft and make sure that the cam lobes are facing downwards. 15. Install two knock pins into the cylinder. 16. Install the cylinder head gasket. 5 of 8 © 2004 Dano’s Bike Shop...
  • Page 6 17. Install the green gasket onto the bottom left cylinder stud and place a black gasket into the recessed hole. 18. Install the cylinder head. Make sure to pull the cam chain all the way through and temporarily lock it into place with a small screwdriver. 19.
  • Page 7 20. Tighten the cam chain roller bolt, the cylinder head side bolt and the cylinder side bolt to 8 ft. lbs. At this point you are now ready to install the cam gear and set the valve clearance. Before installing the cam gear, double check that the engine is at top dead center by lining up the "T"...
  • Page 8 2. Starting with the upper tappet, use a .05mm (.002) feeler gauge to set the valve clearance. Once the gap has been set, tighten the tappet bolt (9mm) to 80 in. lbs. Repeat the process for the lower tappet. 3. After the valve clearance has been set, grab the flywheel and turn the engine over counterclockwise TWICE and re check the valve clearance.