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Author Topic: Stock Honda Technical Articles  (Read 1453 times)
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Mike Wayne
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« on: October 19, 2016, 11:16:12 AM »
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Hi all,

Just thought I'd post these technical articles, they're a handy reference for a new starter or even as a reference when at the track. Don't forget these are USA based so some of the articles aren't relevant, so use you discretion!

http://srsengines.com/technical-library/shifter-kart-engines/

1   2001 Honda CR125 Power Unleashed 
2   Stock Honda CR125 Cylinder Comparison   
3   SRS Engines Hybrid Float-Twin Pump Carb System 
4   Cooling Stock Honda CR125 Engines 
5   Best Reeds for SKUSA Stock CR125 Shifter Karts   
6   Honda CR125 Cold Weather Jetting
7   Pump-Around Carb System Installation 
8   Why PWK or PWM - Stock Moto CR125 Carbs for SKUSA 
9   Summer Tunes 
10   VolksKart - Stock Honda Shifter - The People's Class   
11   Best Stock Honda CR125 Shift Points   
12   Shift Happens 
13   Octane Requirements for Spec Honda 125 Shifter Kart Engines 
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Mike Wayne
South Australia
#51 Stock Honda
Sqizzy
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« Reply #1 on: October 25, 2016, 04:59:50 AM »
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I hear people running to thier karts to find out what *MY* barrels they have....hahahaha...
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Owen
"hunting the Fiddler"
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Mike Wayne
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« Reply #2 on: October 25, 2016, 10:08:17 AM »
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Dunno what exactly that means Squizzy, but here's some more technical articles for anyone who's interested. As with the first ones, these are from a US based supplier so I've added some notes to suit Australian Stock Honda's, but everything is more or less the same.

http://swedetechracingengines.com/techinfo/?cid=62993

Spark Plug
Standard Size - NGK BR10EG or R7376-10

Shorty Style - NGK R7282-10
Must use the NGK TRS1225 Plug cap with short style plugs

** You must use a resistor type spark plug **
 Spark Plug Gap – 0.024” – 0.028”

Oil

Transmission Oil
Motul Trans Oil 10w30 or Motul Trans Oil Expert 10w40

New engine-650ml (21.9 oz)
Use 50ml less for routine oil changes ( 20.0 oz )

We recommend changing the gearbox oil every 4 hours. Oil is cheap compared to the cost of replacing clutch or gearbox parts. If possible, change the oil while the engine is warm.

Two-Stroke Engine Oil

Motul Kart Grand Prix or Maxima 927
Australia Note: Many here also use Elf 976 and Castrol 747 without Issues.
32:1 for break-in and regular use (626ml per 20L )
20:1 has also been successfully used (1L per 20L)
 ** DO NOT USE PUMP FUEL ** Recommend VP C12 or AV Gas

Jetting

The Stock Moto Engine for karting application will not run properly run on pump fuel. SwedeTech recommends the use of VP Racing Fuel’s C12 product.

Keihin 38mm PWM - recommended by SwedeTech

Jetting range is based on Sprint Kart setup using the SwedeTech GFS system and a 1999 cylinder combo.

 160  -180 main (centre of the carb, 6mm hex ) **Recommended to start with a 182 jet and work your way down from there
 Main jet supplies fuel from ½ throttle to full throttle
 50 - 60 pilot ( next to main jet, use 5mm flat screwdriver to remove )
 Pilot jet supplies fuel from 0 – ¼ throttle
 DGJ needle - 3rd from top. Experiment with 4th & 2nd clip from top.
 Needle regulates fuel from 1/8 throttle to ¾ throttle
 Air Screw (side of carburettor body, above fuel inlet ) – 1 Turn

* For new engines purchased directly from SwedeTech and engines maintained by SwedeTech, we offer a jet chart to help customers tune their engine for optimum performance.

Clutch adjustment

You need about 3/8" to 1/2" free play at the end of the lever lifter arm on the engine. You shouldn’t have more than 1 inch of travel when you engage the clutch lever.  When the clutch lifter arm is at rest, it should sit at a downward 45 degree angle.  As you engage the clutch arm, the clutch should start to have an applied load when the lifter arm is at a 90 degree angle to the case or flywheel cover.

Any more than that and the outer plate could jump out of the basket. Make sure your cables have the nylon inner housing and keep them straight and well lubricated. You should not need more than two fingers to engage the clutch.

SwedeTech Quick Tips

Break-in water temperature should be 150° - 155° F (65° - 68° C)

Normal running condition water temperature between 125° - 135° (51° - 57° C)

Take the reading anywhere between the cyl. head outlets and the radiator.  Do not place the water temp sensor between the radiator and the water pump
 Engine will lose performance after 135° (57° C) water temp.

Overheating and engine damage can occur with temperatures past 160°

New engine break-in 15-20 laps.

New Top End break-in 12-15 laps

Increase main jet 1-2 sizes for break-in

RPM Range – 7,000 – 12,700
  

Top End Maintenance

Top End Kit – Piston, ring, circlips, wrist pin, bearing, head gasket, exhaust o-rings, and base gasket.
 For normal use – 6 – 8 hours
 For optimum performance – 4 – 6 hours

Normal use – for the recreational racer that is looking for longevity and cost effectiveness. Typical normal use includes jetting the engine on the richer side.

Optimum Performance – for the avid racer that is looking for every performance advantage. Optimum performance includes jetting the engine for best performance.

Note that the above schedule of maintenance is based on our experience. You may find that these times may be adjusted based on your needs, driving conditions, and overall engine maintenance. Many factors affect wear and tear on components.

Lower End Maintenance

Lower end maintenance will require that you send the engine to SwedeTech. We recommend that this service is performed between 30 - 40 hours of use.

Note that the above schedule of maintenance is based on our experience. You may find that these times may be adjusted based on your needs, driving conditions, and overall engine maintenance. Many factors affect wear and tear on components.

Regular Maintenance

Inspect fuel filter and fuel system for debris (Daily)

Drain transmission oil (4 hours)

Rebuild GFS rectangle fuel pump (4 hours)

Rebuild GFS round fuel pump (16 hours)

Drain GFS pulse lines (Daily)

Replace carburetor float needle valve (with each Top End)

Frequently Used Parts and Part Numbers

Piston,  13110 KZ4 506
 Online Store
http://dev.shopswedetech.com/product.php?productid=85&cat=67&page=1

Ring,    13121 KZ4 A91
 Online Store
 http://www.shopswedetech.com/product_p/13121%20kz4%20a91.htm

Bearing, 91103 KZ4 B01
 Online Store
 http://www.shopswedetech.com/Bearing_Top_End_Wrist_Pin_91103_KZ4_B01_p/91103-kz4-b01.htm

Circlip(2), 94601 15000
 Online Store
 http://www.shopswedetech.com/Circlips_94601_15000_p/94601-15000.htm

Wrist pin, 13111 KV3 000
 Online Store
 http://www.shopswedetech.com/13111_KV3_000_Wrist_Pin_p/13111-kv3-000.htm

Gasket, head , 12251 KZ4 701 (99) --
 Online Store
 http://www.shopswedetech.com/product_p/12251%20kz4%20701.htm

Gasket, base ,12191 KZ4 J00 (99) --
 Online Store
 http://www.shopswedetech.com/product_p/12191%20kz4%20j00.htm

o-ring, exhaust
 Online Store
 http://www.shopswedetech.com/Exhaust_O_ring_p/o-rings%20-%20exhaust.htm

Torque Specs

Nut, 8mm cylinder head  28 nm, 20 ft / lbs
Nut, 8mm cylinder base 28 nm, 20 ft/ lbs
Stud, 8mm Cylinder (case/head) 12 nm, 9 ft / lbs – apply loc-tite
Stud, 6mm Cylinder (exhaust) 10 nm, 7 ft / lbs – apply loc-tite
Impeller, water pump 12 nm, 9 ft / lbs
    

 


  
 
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Mike Wayne
South Australia
#51 Stock Honda
hjtrbo
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« Reply #3 on: October 25, 2016, 01:17:44 PM »
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Hi Mike,

This what I have run for the last 4 years. Hope it helps out a new comer

Brake Pads
Soft compound front & rear

Sprockets
Front 20
Rear 23, 24 & 25

Chain
DID 428 Gold (non o-ring)

Tyres
Dry - MG Yellow
Wet - Dunlop KT14

Spark Plug
NGK BR10EIX

Gearbox Oil
Castrol MTX (650ml dry, 600ml routine drain & change)

Two Stroke Oil
Castol A747 @ 20:1 for break in and racing.

Chain lube
Motul Road (every race)

Bearing lube
Lanox MX4 Lanolin (Front - flush & spray every race meet. Rear - every race)

Fuel
AVGAS 100LL

Jetting
Required mains 175 to 185 (needed a 188 for Mallala the other week!)
Needles DGH, DGJ, DGK
Pilot 60 - Never changed it

Hope it helps someone
NP
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Nathan Pryor
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Mike Wayne
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« Reply #4 on: October 25, 2016, 02:02:09 PM »
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Cheers Nathan. I might try and consolidate all the info into one post and put it as a sticky on the forum.
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Mike Wayne
South Australia
#51 Stock Honda
Sqizzy
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« Reply #5 on: October 25, 2016, 04:52:57 PM »
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Don't the Yanks use pump fuel.?
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Owen
"hunting the Fiddler"
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Mike Wayne
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« Reply #6 on: October 25, 2016, 07:08:15 PM »
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They used to and I think they've slowly moved over to VP C12 as SwedeTech recommend)
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Mike Wayne
South Australia
#51 Stock Honda
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