Cygnus X Bore Up Kit (155.

6 cc) Instruction Manual

Item No. ：０１−０５−４４６０ (Without cam)

CO
：０１−０５−４４６１ (Cam included)
Applicable to：Cygnus X (XC125)
Thank you for purchasing one of our TAKEGAWA’s products. Please strictly follow the following instructions in installing and using the products. Before
fitting the products, please be sure to check the contents of the kit. Should you have any questions about the products, please kindly contact your dealer.

Features
・This is a bore up kit comprising of a cylinder and a piston, utilizing a stock cylinder head.
・This increases bore diameter from 52.4mm to 58.5, and engine displacement from 124 cc to 155, and compression ratio from 9.5:1 to about 11.4:1.
・The aluminum bore surface of the cylinder included in this kit is ceramic-coated. This keeps back the seizing and improves sliding.

Please read the following instructions before installation.

！Caution about fuel to use！
This product is so designed to achieve a higher compression ratio than stock engines. As for the fuel, high-octane gasoline should always be used. In
case regular gasoline is used, abnormal combusiton takes place, and the engine cannot achieve its original performance. Moreover, it is highly likely that
the piston will break down, leading to serious failure of the vehicle. Before installing, make sure that no regular gasoline remains in the fuel tank. In case
regular gasoline is remaining in the fuel tank, do replace it with high-octane gasoline.

！Caution about spark plug！

PY
Be sure to replace a spark plug with a hot-type spark plug CR8E (NGK) with high thermal value, or a hotter-type one. Subsequently, choose and use a
right spark plug with the right level, depending on the degree of burning of the spark plug electrode section.

◎ We do not take any responsibility for any accident or damage whatsoever arising from the use of the products not in conformity with the instructions in
 the manual.
◎We shall be held free from any responsibility or compensation whatsoever for any glitch in parts other than ours if the glitch takes place after installation
 and use of this product.
◎ If you make alterations to the products, we shall be held free from any guarantee of them.
◎ You are kindly requested not to contact us about the combination of our products with other manufacturers'.
◎ This kit is designed for exclusive use in the above-mentioned type of motorcycle only. (and frame number) Please take note that this product cannot be
 mounted on other types of motorcycles.
◎ Fix this product correctly, referring to a right YAMAHA genuine parts service manual for your vehicle.
◎Before installation, prepare right tools and perform the work, strictly following the installation procedure with great care. Besides, this instruction manual,
 as well as a YAMAHA genuine parts service manual, is written with those persons in mind who have basic skills and knowledge in tuning.       
 Therefore, we recommend those who are technichally inexperienced or do not have enough tools to ask a technically-reliable specialist shop for the  
 work.
◎ Clearance between a piston and a cylinder is designed to be narrow. Therefore, never forget to do shakedown.
◎ Because of its high compression ratio and improved airtightness, you will have to press down hard on the kick pedal when kick starting. Further, it may
 be some times difficult to start with a self-starter even when the battery is fully charged.
◎ The installaiton of this product increases the heat release value of the engine, caused by the increase in power. Therefore, this kit is inadequate for the
 long-time high-load driving.
◎ Some of bolts, nuts, dowel pins and packing will be reused. However, be sure to replace worn-down or severely-damaged ones with new ones.

The following show the envisioned possibility of injuries to human bodies and property loss as a result of disregarding the following
CAUTION cautions.
・Work only when the engine and the muffler are cool. (Otherwise, you will burn yourself.)
・Prepare right tools for the work, and do the work in the proper and right way.
  (Otherwise, improper work could cause breakage of parts or injuries to yourself.)
・Always use a torque wrench to screw bolts and nuts tight and securely to the specified torque.
  (Improper torque could cause these parts to get damaged or fall off.)
・As some products and frames have sharp-pointed or protruding portions, please work with your hands protected.
  (Otherwise, you will suffer injuries.)
・Before riding, always check every section for slack in parts like screws. If you find slack ones, screw them securely up to the specified torque.
  (Or improper torque may cause parts to come off.)

The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the
WARNING following cautions.
・Always drive the engine in a well-ventilated place, and do not switch on the engine in an airtight place.
  (Otherwise, you will suffer from carbon monoxide poisoning. )
・When you notice something abnormal with your motorcycle while riding down a road, stop riding immediately and park your motorcyle in a safe  
  place. (Otherwise, the abnormaility could lead to an accident.)
・Before doing work, place the motorcycle on level ground to stablize the position of your motorcycle for safety's sake.
  (Otherwise, your motorcycle could fall down and injure you while you are working.)
・Check or perform maintenance of parts correctly according to the procedures in the instruction manual or a service manual.
  (Improper checking or maintence could lead to an accident.)
・If you find damaged parts when checking and performing maintenance of your motorcycle, do not use these parts any longer, and replace them  
  with new ones. (The continued use of these damaged parts as they are could lead to an accident.)

-1- Dec./08/’
06
◎ Please be informed that, mainly because of improvement in performance, design changes, and cost increase, product specifications and prices are
 subject to change without prior notice.
◎ A defective product which we acknowledge is caused by product materials or defect in manufacturing will be repaired or replaced with a new one
 by us at our expense, if and when a claim is filed with us within one (1) month of your purchase. However, replacing of parts shall be made at users’
 expenses. And we shall be held free from responsibility for any defect caused by improper installation or use.
◎ You are requested to keep this instruction manual until you discard this product.

CO
∼ Kit Contents ∼
５ １
９ No. Parts Name Qty
１ Piston １
２ Piston ring set １
２
３ Wrist pin １
４ Wrist pin circlips ２
４ ５ Cylinder １
６ Cylinder head gasket １
３
７ Cylinder gasket １
７ ６
８ Tenstioner lifter gasket １
８ ※９ Camshaft １
※ A camshaft is not included in Item No. of 01-05-

PY
 4460.

∼ Installation Procedures ∼
◇ Before doing work, place the motorcycle on   2. Junctions ●Air Shroud Removal
 level ground to stablize the position of your ◇ With reference to YAMAHA genuine parts ◇ Remove pan screws and tapping screws, and
 motorcycle. As to the following procedures,    service manual, disconnect the following parts.  remove a fan air shroud.
 work only when the engine and the muffler are ・Negative pressure hose on the manifold ◇ Remove tapping screws, divide right and left
 cool. (Otherwise, you will burn yourself.) ・Spark plug cap  side cylinder air shrouds, and remove them.
・Blow-by gas hose on the cam sprocket cover
●Parts Removal ・Secondary air supply pipe on the cylinder head ●Spark Plug Removal
1. Body Cover Manifold ◇ Remove a spark plug.
◇ With reference to YAMAHA genuine parts
 service manual, remove following parts. ●Cam Sprocket Removal
・Front cover ◇ Remove a cam sprocket cover and O-ring.
・Fuel-pump-mounting bolts ◇ Rotate a flywheel clockwise, and align an “I”
・Seat / trunk Hose   mark on the cam sprocket with an “ △ ”mark
・Seat lock on  the cylinder head. This position is at what is
・Standing handle Hose
  called TDC (Top Dead Center) on the
・Left / Right side covers  compression stroke.
・Tail light unit
・Left / Right side mauls Hose
・Under cowl
・Foot rest board
“I” mark

Alignment
mark

Spark plug cap

Pipe
Cylinder head Cam sprocket cover ◇Holding the flywheel, loosen a cam sprocket  
 bolt. Remove a cap bolt of the cam chain    
●Carburetor Removal  tensioner and take out a spring.
◇Loosen the carburetor clamp on the manifold, and ◇ Unfasten the cam sprocket bolts and remove
 disconnect the carburetor.  breather plate and cam sprocket.
◇Remove bolts and the cam chain tensioner frm
●Exhaust Pipe Removal  the cylinder.
◇ Remove two nuts on the cylinder head.
◇Remove bolts on a rear arm, and remove an   
 exhaust pipe.

-2- Dec./08/’
06
●Removal of Cylinder Head, Cylinder,   ◇ Detach the rocker arm shafts both on intake and ◇ Fix piston rings to the piston. Letters “1R” and
 exhaust sides with a sliding hammer.  “2R” are engraved on the top and second rings
 and Piston
 Special tool to use: Sliding hammer  respectively. Be sure to fix the rings so the  
◇ Loosen the nuts / washers and bolts on the  
 Yamaha-made genuine tools:  sides with the engraves letters face upwards.
 cylinder head in a few steps in the following  
 ・Balancer shaft puller bolt: (90890-01085) ※Be careful not to damage the piston or break  
 order as shown in the figure below.
 ・Weight: (90890-01084)    the rings.

CO
◇ Apply engine oil to kit’s wrist pins, pin hole on
 the piston, and to an end on a connecting rod.
 Fix the piston to the connecting rod with the  
６ ４  arrow on the top of the piston facing the
２  exhaust side, and then fix the wrist pin circlips
 included in the kit.
１ ◇ Apply engine oil to the piston rings, and make
３ ５  sure than the rings turn smoothly.
Sliding hammer Letter
Letter Top ring

◇Remove two dowel pins and a cam chain guide. ◇ Attach a bolt of the cam sprocket to the
 If you find no wear or damage upon checking,  camshaft, and pull out the camshaft from the
 reuse them.  cylinder head. Second ring
◇ Remove the cylider and two dowel pins. If you ※ Never pull it out forcibly.
 find no wear or damage upon checking, reuse Side rails

PY
 them. Expander
◇ Remove wrist pin circlips, pull out a wrist pin,
 and remove the piston.
Wrist pin’s direction Right angle of the wrist pin
※Plug the opening on the crank case with a   
 waste cloth not to get any foreign material in it.
◇ Completely get rid of the gasket scraps
 remaining on the mating surface to the cylinder Piston
 with a scraper or the like.

●Change of camshaft ◇ Apply engine oil to the cam on the provided ●Cylinder Installation
 camshaft and to the bearing, and install the bolt, ◇ Remove the waste cloth plugged in the
 (in the case of a cam being provided.)
 and install the camshaft to the cylider head.  opening.
◇ Remove a tappet cover and O-ring both for  
Apply oil here. ◇Check, through the cam chain hole, whether  
 intake and exhaust, and loosen the adjust nut
 the cam chain has not come off the sprocket on
 and adjust screw on the rocker arm.
 the crank shaft.
◇Degrease the mating surfaces of the crank case
 and the cylinder with thinner or the like, and fix
 dowel pins and cylinder gasket included in the
 kit.
◇ Fit the cylinder into the piston little by little with
 fingers, being careful not to shift the piston ring’s
Apply oil here.  end gaps out of the position, and then fit the
 cylinder into the crank case.
◇Turn the cam toward the combustion chamber,  
※When the piston is fitted into the cylinder, pass
 and install the rocker arm and stopper plate.
 the cam chain through the cylinder.
Adjust nut
◇ Degrease the upper surface of the cylinder,  
● Piston Installation  and fix two dowel pins and a kit’s cylinder head
◇ Remove the bolt and stopper plate.
◇Install a wrist pin circlip to one of the pin holes on
 gasket. Fit the cam chain guide precisely to the
 the piston.
 groove on the cylinder.
※Attach the piston pin circlip so the ring end gap  
Stopper  does not meet with the notch on the piston pin  
plate  hole, and ring end gap should be either on the top
 or at the bottom of the hole as illustrated in the  
 figure below.
Circlip

Notch End gap

-3- Dec./08/’
06
●Cylinder Head Installation ●Cam Chain Tensioner Installation ◇ Tighten all loosely-tightend nuts, bolts and
 washers to the specified torque.
◇Degrease the mating surface of the cylinder   ◇ Turn up a one-way pawl on the cam chain   
 Specified torque
 head with thinner or the like. Pass the cam chain  tensioner, and press a tensioner rod into it.
 Cylinder head nut : 13 N・m (1.3kgf・m)
 through the cylinder head and install the ◇Install a provided gasket and cam-chain tensioner
 Rear arm bolt : 31 N・m (3.1kgf・m)
 cylinder head.  to the cylinder with two bolts.
 Rear arm bolt / washer
 Loosely tighten four washers / nuts and two  Ｏ Install a ring, spring and cap bolt.

CO
  : 53 N・m (5.3kgf・m)
 bolts to the stud bolts. Tighten nuts to the  Specified torque:
 specified torque in several speps in order of     Tensioner mounting bolt Bolt / washer
 the numbers in the figure below.       : 9 N・m (0.9kgf・m)
 Specified torque    Cap bolt : 8 N・m (0.8kgf・m)
  Cylinder head nut : 22 N・m (2.2kgf・m) ◇ Rotate the crank shaft clockwise, and check that
  Cylinder head bolt : 10 N・m (1.0kgf・m)  “I” mark on the cam sprocket is aligned with the  
 alingment mark on the cylinder head when the ”T”
 mark on the flywheel is aligned again with the
 “｢” alignment mark on the crankcase cover.
Bolt
３ ◇ Attach a cover on the cam chain tensioner. Bolt
１
５
●Adjustment of valve clearance: ●Carburetor Installation
６  (In the case of a cam being provided.) ◇ Insert the carburetor into the manifold, and  
◇ Insert a thickness gauge between the adjusting  tighten a carburetor clamp to fix the carburetor.
４ ２  screw and valve stem to adjust the valve
 clearance. Holding the adjusting screw, tighten   ● Parts Reinstallation

PY
 up the lock nut. ◇ With reference to YAMAHA genuine parts
 Valve clearance: 0.04 ∼ 0.07 mm both for intake  service manual, reinstall or connect all the
 and exhaust.  removed parts.
 Specified torque : 7 N・m (0.7kgf・m)
●Cam Sprocket Installation
◇ Install the cam sprocket cover and O-ring with   ● Engine Starting
◇Check that the “I” mark on the flywheel is still  
 two bolts.
 aligned with the“△”mark on the crank case. 1. About fuel
 Specified torque : 7 N・m (0.7kgf・m)
Flywheel ◇ High-octane gasoline should always be used.
◇Install a tappet cover and O-ring for both intake  
◇ When regular gasoline is remaining in the fuel
 and exhaust with three bolts each.
 tank, always replace it with high-octane
 Specified torque : 7 N・m (0.7kgf・m)
 gasoline.

2. Final Checking
◇ Check every section for slacks in screws, nuts
●Spark Plug Installation  or the like.
◇Make sure that engine oil is remaining in a
Crank case ◇ Install a spark plug.
 specified amount or more.
 Specified torque : 13 N・m (1.3kgf・m)
◇Drive the engine in a well-ventilated safe place
※ Be sure to replace the spark plug with the one  
 with great care. Keep the engine idling for about
 with high thermal value of CR8E (NGK) or the  
◇ Install the cam sprocket to the cam chain,  5 minutes so the engine oil gets circulated all  
 higher one.
 aligning the “I” mark on the cam sprocket with  around the engine.
◇ Install and tighten the spark plug cap securely.
 the “ △ ” mark on the cylinder head. ◇Check that there is no abnormal noise from the
※ Fix the cam chain so the lower part of it (at the  engine or oil leak in every gasket.
●Air Shroud Installation
 exhaust side) is stretched tight. ◇Shut off the engine and wait for it to be cool.  
◇ Put together the left and right side cylinder air  
 Then double check each section for slack in  
Slack  shrouds, and fix them with tapping screws.
 screws and nuts.
“I” mark  Be careful not to jam a heat protector.
◇ Install a fan air shroud with a tapping screw and
Alignment ●About Shakedown
 pan screw.
mark ◇ We have designed the clearance between
 piston and cylinder narrow. So, refrain from  
● Exhaust Pipe Installation  sudden acceleration, and, in addition, never fail
◇ Loosely tighten two nuts on the cylinder head    to carry out shakedown for about 100 km at  
Tense  side.  reduced engine revolutions.
◇Aligning the notch on the cam shaft with the   ◇Temporarily fix the exhaust pipe onto the rear arm
 cam sprocket pawl, fix a breather plate and    with a bolt & washer.
 bolts. While holding the flywheel, tighten cam 3-5-16 Nishikiorihigashi Tondabayashi
 sprocket bolts. Osaka Japan
 Specified torque : 30 N・m (3.0kgf・m) TEL : 81-721-25-1357
FAX : 81-721-24-5059
URL : http://www.takegawa.co.jp

-4- Dec./08/’
06