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DAYTONA 150E ENGINE 

Owner's Manual

 

Page 2/57 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

INTRODUCTION 

Congratulations on your purchase of a DAYTONA 150E Engine. 

This manual explains operation, inspection, basic maintenance and tuning of the engine. 

If you have any questions, please contact the dealer you purchased the engine/bike from. 

Please read this manual very carefully before use. 

 

 

WARNING

 

1.  DAYTONA 150E  ENGINE is designed strictly FOR  COMPETITION USE, ONLY ON  A 

CLOSED  COURSE.  It  is  illegal  to  use  this  engine  on  any  public  road  or  highway. 

Off-road use on public space is also illegal.   

Please check local regulation before use. 

2.  This engine is to be used by an EXPERIENCED RIDER ONLY. 

Fatal accident may be caused unless it is used by experienced riders or maintained by 

professional and experienced mechanics. 

3.  This engine is to be maintained by professional and experienced mechanics. 

Serious damage may occur, otherwise. 

4.  This manual explains ONLY THE BASIC operation, inspection, maintenance and tuning, 

but  it  is  customer’s  responsibility  to  maintain  the  engine  to  the  best  possible 

performance, depending on the circumstances of the time. 

 

Summary of Contents for 150E

Page 1: ...DAYTONA 150E ENGINE Owner s Manual ENGLISH MANUAL SECTION Page 2 24 VERSION FRANCAISE Page 25 47 PARTS CATALOGUE SECTION Page 48 57 CATALOGUE DES PIECES DATACHEES Page 48 57 corp...

Page 2: ...to use this engine on any public road or highway Off road use on public space is also illegal Please check local regulation before use 2 This engine is to be used by an EXPERIENCED RIDER ONLY Fatal a...

Page 3: ...s not originally equipped on Products This includes DAYTONA UPGRADE KIT PARTS as well since those are designed for the top competition riders 3 Abnormal strain neglect or abuse 4 Accident or collision...

Page 4: ...NCE SPECIFICATIONS Page 7 10 MAINTENANCE INTERVALS Page 11 13 PRE OPERATION INSPECTION AND MAINTENANCE Page 14 ENGINE OIL LEVEL INSPECTION Page 14 CARBURETOR SETTING Page 15 16 IGNITION TIMING SELECTI...

Page 5: ...DAYTONA 150E ENGINE Owner s Manual Page 5 57 PART NAMES...

Page 6: ...Oil SAE 10W 40 or higher grade API SG or higher grade Engine oil capacity Periodic oil change With oil filter replacement Total amount 0 60 L 0 65 L 0 70 L Need more amount of oil when oil cooler is i...

Page 7: ...er head Warp limit 0 05 mm 0 002 in Cylinder Bore size Out of round limit 57 00 57 015mm 2 2441 2 2445 0 05 mm 0 002 in Camshaft Drive method Cam dimensions Intake A B Exhaust A B Chain drive Left 26...

Page 8: ...EX 27 9 28 1 mm 1 0984 1 1062 in 23 4 23 6 mm 0 8897 0 9291 in 0 8 1 0 mm 0 0314 0 03937 in 0 8 1 0 mm 0 0314 0 03937 in 4 970 4 985 mm 0 19566 0 1962 in 4 970 4 985 mm 0 19566 0 1962 in 5 000 5 012...

Page 9: ...98 mm 0 5116 0 5117 in 0 1mm 0 004 in 13 06 mm 0 5141 in 12 97 mm 0 5106 in Piston rings Top ring Dimensions B T End gap installed Side clearance installed 2nd ring Dimensions B T End gap installed Si...

Page 10: ...ree play F 40 2 mm 1 58267 in 0 03 one side 0 1 0 35 mm 0 0039 0 0137 in 0 1 mm 0 0039 in 0 6 mm 0 0236 in Clutch Friction plate thickness Quantity Clutch plate thickness Quantity Warp limit Clutch sp...

Page 11: ...heck the valve clearances Inspect Replace The engine must be cold Check the valve seats and valve stems for wear VALVE SPRINGS Inspect Replace Check the free length and the tilt CAMSHAFTS Inspect Repl...

Page 12: ...INDER HEAD Inspect and clean Replace Inspect carbon deposits and eliminate them Change gasket CYLINDER Inspect and clean Replace Inspect score marks Inspect wear CLUTCH Inspect and adjust Replace Insp...

Page 13: ...Every third or 500 km Every fifth or 1 000 km As requir e ed Remarks SPARK PLUG Inspect and clean Replace OIL COOLING SYSTEM Option Check hoses leakage Replace hoses and gaskets AIR FILTER Option Clea...

Page 14: ...g this engine check the following points ENGINE OIL LEVEL INSPECTION 1 Start the engine warm it up for several minutes and then turn off the engine and wait for a few minutes 2 Place the bike on a lev...

Page 15: ...erates correctly and opens and closes smoothly It is highly recommended that the carburetor setting is performed by an experienced mechanic to obtain the best possible performance Atmospheric conditio...

Page 16: ...ay 3 Jet Needle Needle Jet 4 Main Jet 1 2 3 4 1 8 1 4 Closed 1 2 3 4 Full Open Here is the recommended setting information of KEIHIN PE28 carburetor for your reference Tested Conditions Carburetor KEI...

Page 17: ...unit WIRE CONNECTION TABLE Color of Wire WHITE GREEN YELLOW GREEN Remarks Timing 1 Factory Default Setting No wires to be connected Timing 2 Timing 3 Timing 4 Notes a Timing 1 gives more torque at lo...

Page 18: ...egrees Fahrenheit It is solely customer s responsibility to control the engine oil temperature Any failures caused by overheating are NOT considered as the defects of Products It is highly recommended...

Page 19: ...age 19 57 ELECTRICAL DIAGRAM BLUE For Tachometer Pulse Pickup BLACK Ground BLUE Primary Coil RED GREEN WHITE YELLOW Charging LIGHT GREEN YELLOW Engine Stop 2P COUPLER ACG ROTOR CDI UNIT MAIN HARNESS S...

Page 20: ...llowing temp gauge and fitting are available from Daytona The temp gauge 47101 can be used with the Daytona oil cooler 61785 by using the Daytona sensor fitting 43350 Daytona Part 61785 7 Core Oil Coo...

Page 21: ...Page 21 57 OPTIONAL PARTS REINFORCED CLUTCH FRICTION DISC REINFORCED CAM CHAIN Daytona Part 84750 Reinforced cam chain 88 Link 25HS Solid Bushing Made in Japan Daytona Part 84749 Reinforced clutch fr...

Page 22: ...THE INSTALLATION OF THESE OPTIONAL PARTS ARE NOT CONSIDERED AS THE DEFECTS OF PRODUCTS PE28 CARBURETOR CARBURETOR SETTING PARTS Daytona Part 83952 Keihin PE28 Carburetor Daytona Part 31123 Main Jet Se...

Page 23: ...the top competition riders ANY FAILURES CAUSED BY THE INSTALLATION OF THESE OPTIONAL PARTS ARE NOT CONSIDERED AS THE DEFECTS OF PRODUCTS DOHC CYLINDER HEAD AND CYLINDER KIT This upgrade kit soups up D...

Page 24: ...ARTS WARNING Since these UPGRADE KIT PARTS are designed specifically for the top competition riders ANY FAILURES CAUSED BY THE INSTALLATION OF THESE OPTIONAL PARTS ARE NOT CONSIDERED AS THE DEFECTS OF...

Page 25: ...errain ouvert au public est strictement interdite par les lois en vigueur Veuillez observer toutes les lois et r glements applicables avant utilisation 6 Ce moteur ne peut tre utilis que par UN PILOTE...

Page 26: ...t l utilisateur 9 Installation de pi ces ou accessoires qui ne sont pas d origine Ceci inclut les pi ces Racing Daytona r serv es la comp tition telles que la culasse 4 soupapes 10 Contraintes anormal...

Page 27: ...ERALES Page 29 CARACTERISTIQUES ENTRETIEN Page 30 33 CALENDRIER D ENTRETIEN Page 34 36 CONTROLE AVANT UTILISATION ET ENTRETIEN Page 37 CONTROLE DU NIVEAU D HUILE Page 37 REGLAGE DU CARBURATEUR Page 38...

Page 28: ...DAYTONA 150E ENGINE Owner s Manual Page 28 57 DESIGNATION DES PIECES...

Page 29: ...tion Carter humide Huile moteur recommand e SAE 10W 40 ou indice sup rieur API SG or ou indice sup rieur Capacit huile moteur Vidange Avec remplacement du filtre Total 0 60 L 0 65 L 0 70 L capacit d h...

Page 30: ...inder head Warp limit 0 05 mm 0 002 in Cylinder Bore size Out of round limit 57 00 57 015mm 2 2441 2 2445 0 05 mm 0 002 in Camshaft Drive method Cam dimensions Intake A B Exhaust A B Chain Left 26 49...

Page 31: ...EX 27 9 28 1 mm 1 0984 1 1062 in 23 4 23 6 mm 0 8897 0 9291 in 0 8 1 0 mm 0 0314 0 03937 in 0 8 1 0 mm 0 0314 0 03937 in 4 970 4 985 mm 0 19566 0 1962 in 4 970 4 985 mm 0 19566 0 1962 in 5 000 5 012...

Page 32: ...998 mm 0 5116 0 5117 in 0 1mm 0 004 in 13 06 mm 0 5141 in 12 97 mm 0 5106 in Piston rings Top ring Dimensions B T End gap installed Side clearance installed 2nd ring Dimensions B T End gap installed S...

Page 33: ...ree play F 40 2 mm 1 58267 in 0 03 one side 0 1 0 35 mm 0 0039 0 0137 in 0 1 mm 0 0039 in 0 6 mm 0 0236 in Clutch Friction plate thickness Quantity Clutch plate thickness Quantity Warp limit Clutch sp...

Page 34: ...acer Le moteur doit tre froid V rifiez l usure des si ges et des queues de soupape Ressorts de soupape Contr ler Remplacer V rifier la longueur libre et l inclinaison Arbre cames Contr ler Remplacer C...

Page 35: ...LASSE Contr ler et nettoyer Remplacer Contr ler et liminer les d p ts de carbone Changer le joint CYLINDRE Contr ler et nettoyer Remplacer Contr ler l usure EMBRAYAGE Contr ler et r gler Remplacer TRA...

Page 36: ...urses ou 1 000 kms Si n ces saire Remarques BOUGIE Contr ler et nettoyer Remplacer Radiateur d huile Option V rifier les durites les fuites Remplacer les durites et les joints Filtre air Option Nettoy...

Page 37: ...nts CONTROLE DU NIVEAU D HUILE MOTEUR 5 D marrez le moteur laissez le chauffer quelques minutes puis arr ter le moteur et attendez quelques minutes 6 Placez la moto sur un sol plat et maintenez la dro...

Page 38: ...eur fonctionne correctement et que le moteur acc l re ou ralenti progressivement Il est fortement recommand de faire r gler le carburateur par un m canicien exp riment pour obtenir les meilleures perf...

Page 39: ...utaway 3 Jet Needle Needle Jet 4 Main Jet 1 2 3 4 1 8 1 4 Closed 1 2 3 4 Full Open Ici vous trouverez les r glages recommand s pour utiliser le carburateur Keihin PE28 pour votre r f rence Conditions...

Page 40: ...C VERT JAUNE VERT Remarques Courbe 1 Courbe d allumage par d faut Pas de fils connect s Courbe 2 Courbe 3 Courbe 4 ATTENTION NE PAS UTILISER LA COURBE 3 ET 4 AVEC LE MOTEUR DAYTONA 150E UNE COMBUSTION...

Page 41: ...rature incombe totalement l utilisateur Daytona ou son distributeur ne pourra tre tenu responsable en cas de dommages TOUT DOMMAGE CAUSE PAR UNE SURCHAUFFE NE POURRA ETRE ASSIMILE A UN VICE DE FABRICA...

Page 42: ...age 42 57 SCHEMA ELECTRIQUE GREEN WHITE RED YELLOW Charging LIGHT GREEN ACG ROTOR 2P COUPLER YELLOW Engine Stop BLUE For Tachometer Pulse Pickup IG COIL TO SPARK PLUG SPARK PLUG CODE BLACK Ground BLUE...

Page 43: ...TURE D HUILE ADAPTATEUR Cette jauge est disponible au catalogue Daytona La jauge 47101 est compatible avec le radiateur d huile Daytona 61785 en utilisant le capteur Daytona 43350 Daytona Part 47101 T...

Page 44: ...44 57 PIECES OPTIONNELLES DISQUE D EMBRAYAGE RENFORCE CHAINE DE DISTRIBUTION RENFORCEE Daytona Part 84750 Reinforced cam chain 88 Link 25HS Solid Bushing Made in Japan Daytona Part 84749 Reinforced cl...

Page 45: ...PTIONNELLES NE POURRA ETRE CONSIDERE COMME ETANT UN VICE DE FABRICATION CARBURATEUR KEIHIN PE28 KIT PIECES POUR PE28 Daytona Part 83952 Keihin PE28 Carburetor Daytona Part 31123 Main Jet Set 8 pcs set...

Page 46: ...n TOUT DOMMAGE CAUSE PAR L INSTALLATION DE CES PIECES OPTIONNELLES NE POURRA ETRE CONSIDERE COMME ETANT UN VICE DE FABRICATION KIT RACING 4 SOUPAPES DOHC Ce nouveau kit 4 soupapes a t con u pour maxim...

Page 47: ...KIT PIECES RACING ATTENTION Ces pi ces sont con ues pour la comp tition TOUT DOMMAGE CAUSE PAR L INSTALLATION DE CES PIECES OPTIONNELLES NE POURRA ETRE CONSIDERE COMME ETANT UN VICE DE FABRICATION DAY...

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