Daytona DT125 Instruction Manual

Finger-follower dohc 4valve cylinderhead upgrade kit, engine narrow pitch

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INSTRUCTION
*Be sure to read and understand the contents before installing the product and use it properly.
*Please keep this instruction manual in a safe place so that you can take it out and read it at any time.
*When transferring this product or the vehicle on which this product is installed to a third party, be sure to also hand over this instruction manual.
Finger-Follower DOHC 4Valve CylinderHead
Thank you for purchasing DAYTONA's product. Please read this instruction manual carefully before using this product.
If you notice any problem, please contact the dealer where you purchased the product.
We are not responsible for any accident or damage caused by using the product without following the precautions in the instruction manual.
Warning
Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury.
If you are technically unskilled or inexperienced, leave the work to an experienced store or mechanic.
Improper installation due to inexperienced skills or lack of knowledge may result in damage to parts or accidents.
Do not run the engine for long periods of time in poorly ventilated areas.
Doing so may result in carbon monoxide poisoning.
Gasoline is extremely flammable, so keep the work area away from fire.
Evaporated gasoline may cause an explosion, so work in a well-ventilated area.
If anything unusual happens while test riding, stop at a safe place and check engine parts.
Indicates a potentially hazardous situation which, if not avoided, could result in personal injury
Caution
or property damage.
The installing of this kit requires jacking up your motorcycle and must be done under trained hands.
Inadequate safety precautions and professional help could result in serious injury.
When working on the engine and muffler, be sure to do so when they are cool.
Doing so while the engine and muffler are hot may result in burns.
Prepare appropriate tools and work equipment to avoid damage or injury to parts.
Be sure to install an oil cooler and oil temperature gauge to control the oil temperature.(Keep under 110degree C)
Continuous running at high temperatures may damage the engine.
Check and maintain the oil pump and the strainer (wire mesh) at the bottom of the pump.
After having installed the new parts, place check each part installed and tighten all nuts, bolts and screws
after having ridden 100km. Regular inspection of parts should be done on every 500km.
For spark plugs, use the specified product, NGK ER8EH.
Be sure to use high-octane gasoline. Regular gasoline cannot be used because of the high compression engine.
Avoid sudden engine braking by downshifting.
In the worst case, this will result in damage to the crankshaft and engine.
This product has some related parts required.
In this manual, the installation procedure is omitted for related parts products. Please note.
The price and specifications of this product are subject to change without notice.
The same applies to the products introduced in the text. Please note.
UPGRADE KIT
Be sure to check the contents of the product before installation.
Completely revised DOHC 4-valve cylinder head
Adopted finger follower rocker arms
Port geometry designed to increase intake volume and velocity
Ceramic coated all aluminum cylinder
Forged 2-ring piston, crankshaft with long connecting-rod
■Please read the following before the installation.■
■ Features ■
DLC coated piston pin
MODEL
DT125 Engine
(Narrow Pitch)
R80458 PAGE 1/9
ITEM NUMBER
80458
2021/06/21

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Summary of Contents for Daytona DT125

  • Page 1 UPGRADE KIT (Narrow Pitch) Thank you for purchasing DAYTONA’s product. Please read this instruction manual carefully before using this product. Be sure to check the contents of the product before installation. If you notice any problem, please contact the dealer where you purchased the product.
  • Page 2 RUBBER SET for KEIHIN PE28/PWK28 46758 RUBBER SET for KEIHIN PE24/CR-mini22 28939 DAYTONA has rubber for KEIHIN carburetors. The mounting bolt pitch of the rubber is 58mm. 58mm Engine oil temperature Be sure to install an oil cooler and oil temperature gauge to control the oil temperature.(Keep under 110degree C) Continuous running at high temperatures may damage the engine.
  • Page 3 JOINT, SPARKPLUG CABLE WASHER, SEALING 10mm RUBBER, PLUGCAP WASHE R, SEALING 6mm (Cu) SPARK PLUG (ER8EH) WASHER, SEALING 6mm (AL) GASKET, CYLINDER HEAD WASHER, PLAIN 5mm GASKET, CYLINDER PIN, TIMING SET GASKET, CRANKCASE SOCKET, PLUG (DAYTONA) GASKET, R. CASECOVER STICKER 2021/06/21...
  • Page 4: Crankshaft / Crankcase

    80458 PAGE 4/9 Installation procedures The following procedures are omitted from this manual. Please have the work done by a knowledgeable and experienced person. Perform the necessary work before assembly. Remove the crankcase gasket. Clean and inspect the disassembled parts. If you find any damaged or worn parts, replace them with new ones.
  • Page 5 80458 PAGE 5/9 2. PISTON / CYLINDER #4. PISTON #5. RING SET, PISTON #24. PIN, DOWEL 8X12 (2) #18. GASKET, CYLINDER #2. CYLINDER #7. CIRCLIP (2) #6. PIN, PISTON #23. GASKET, 12MM RUBBER STOCK STOCK 10N-m STOCK Do not tighten in this procedure STOCK #31.
  • Page 6: Cylinder Head

    80458 PAGE 6/9 3. CYLINDER HEAD #11. UNION, 8mm (for BREATHER) 12~15N-m #17. GASKET, CYLINDER HEAD #12. BOLT, M10 #25. PIN, DOWEL 8X14 (2) #34. WASHER, SEALING 10mm #1. CYLINDER HEAD ASSY. STOCK 10N-m Tighten after tightening the cylinder head cap nut #35.
  • Page 7 80458 PAGE 7/9 4. VALVE TIMING SPROCKET #28. BOLT, HEX SOCKET M6X50 10N-m #35. WASHER, SEALING 6mm #38. PIN, TIMING SET #8. SPROCKET, TIMING GREASE #37. WASHER, PLAIN 5mm (3) #29. BOLT, HEX SOCKET M5X15 (3) 8N-m #22. O-RING, G65 #10.
  • Page 8 80458 PAGE 8/9 Determine the position of the sprocket using the pin provided. Secure the sprocket using the M5x15 bolt and washer. Then remove the pin. Tighten the third bolt with the M5x15 bolt. #29. BOLT, HEX SOCKET M5X15 #29. BOLT, HEX SOCKET M5X15 #38.
  • Page 9 80458 PAGE 9/9 Install the O-ring on the timing gear cover. Install the timing gear cover to the cylinder head and secure it with bolts from the other side. #28. BOLT, HEX SOCKET M6X50 10N-m #36. WASHER, SEALING 6mm GREASE #22.
  • Page 10 INSTRUCTION R80458-M PAGE 1/9 *Be sure to read and understand the contents before installing the product and use it properly. *Please keep this instruction manual in a safe place so that you can take it out and read it at any time. *When transferring this product or the vehicle on which this product is installed to a third party, be sure to also hand over this instruction manual.
  • Page 11: Service Data

    80458-M PAGE 2/9 COMPONENTS 2 (Head Cover) NAME NAME COVER, CYLINDER HEAD SIDE BOLT, HEX SOCKET M6x25 COVER, TAPPET BOLT, HEX SOCKET M6X20 GASKET, TAPPET BOLT, HEX SOCKET M6X15 PIN, DOWEL 8X12 BOLT, HEX SOCKET M5X10 SERVICE DATA SPECIFICATIONS Unit : mm ITEM STANDARD LIMIT...
  • Page 12 80458-M PAGE 3/9 DISASSEMBLY When removing the cylinder head cover and cylinder head, take care not to damage the mating surfaces. When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original locations. Remove the bolts on the head cover. Remove the tappet covers.
  • Page 13 80458-M PAGE 4/9 Remove the cover and dowel pin. DOWEL PIN COVER Remove the truss screw and remove Remove the camshafts. the rocker arm shaft. CAMSHAFT ROCKER ARM SHAFT TRUSS SCREW Remove rocker arm and spring. Remove the shim. SHIM SPRING ROCKER ARM Organize each part so that it can be...
  • Page 14: Parts Inspection

    80458-M PAGE 5/9 Remove the valve spring and valve. Remove the stem seal. COTTER RETAINER VALVE SPRING STEM SEAL VALVE, EXHAUST VALVE, INTAKE Organize each part so that it can be put back in its original place. When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original locations.
  • Page 15 80458-M PAGE 6/9 ASSEMBLY Install the new stem seals. Intake side stem seal : STEM SEAL HONDA GENUINE PARTS No. 12209-KY2-003 VALVE GUIDE Exhaust side stem seal : HONDA GENUINE PARTS No. 12209-KT7-013 COTTER Lubricate the valve stems and insert the valve into the valve guide. RETAINER Install the valve springs with the tightly wound SPRING...
  • Page 16 80458-M PAGE 7/9 Install the rocker arm and spring. SPRING ROCKER ARM Insert the rocker arm shaft. Install the truss screw. ROCKER ARM SHAFT The side with the screw should be on the outside. Apply oil to the parts that come in contact. TRUSS SCREW WASHER, PLAIN Install the O-ring on the idle gear shaft.
  • Page 17 80458-M PAGE 8/9 Align the marks on the cam gear and idle gear. CAM GEAR (INT) CAM GEAR (EXH) MARK MARK IDLE GEAR Assemble the cylinder head upper. Check the tappet clearance. 11N-m HEAD UPPER THICKNESS GAUGE Tappet clearance Standard value INT : 0.08±0.03 [mm] EXH : 0.10±0.03 [mm] If it is out of the standard value, replace the shim and adjust it.
  • Page 18 80458-M PAGE 9/9 Install the cylinder head upper. M6X25 M5X25 Tighten the M6 bolts in a crisscross pattern in 2-3 steps to the specified torque. M6X30 Torque value : 11N-m Hex socket bolt M6 5N-m Hex socket bolr M5 M5X25 M6X25 Degrease the mating surface of the cylinder head and sidecover.

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