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© 2004 Dano’s Bike Shop

 

 

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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.  

  

 

 

 

 

Summary of Contents for 88cc

Page 1: ...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 posit...

Page 2: ...p opening on each ring faces the opposite direction 5 Lightly coat the wrist pin with clean motor oil 6 Install the piston onto the crankshaft and secure it into place with the wrist pin Make sure tha...

Page 3: ...2004 Dano s Bike Shop 3 of 8 8 Install the cylinder gasket 9 Install a small black seal into the lower hole 10 Install two knock pins...

Page 4: ...the ring Do not force the cylinder into place Repeat the process for each ring until the cylinder is in place 12 Install the black cam chain roller the cam chain roller bolt 10mm and the cylinder side...

Page 5: ...2004 Dano s Bike Shop 5 of 8 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...

Page 6: ...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 Install the cylinder head gasket...

Page 7: ...d center by lining up the T on the flywheel with the notch on the engine case Once the T is lined up look into the spark plug hole with a flashlight and you should be able to see the top of the piston...

Page 8: ...s been set grab the flywheel and turn the engine over counterclockwise TWICE and re check the valve clearance If you have done everything correctly there should be NO gap clearance If there is a gap y...

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