DAYTONA 150E
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.
- 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 in public space is also illegal. Please check local regulation before use.
- 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.
- This engine is to be maintained by professional and experienced mechanics. Serious damage may occur otherwise.
- This manual explains ONLY THE BASIC operation, inspection, maintenance, and tuning, but it is the customer’s responsibility to maintain the engine to the best possible performance, depending on the circumstances.
CUSTOMER’S RESPONSIBILITY & CUSTOMER SERVICE
GENERAL EXCLUSIONS
Any failures caused by the following reasons are NOT considered defects of the products:
- Overheating due to improper engine oil temp. control.
- ENGINE OIL TEMPERATURE MUST BE CONTROLLED AT 90 DEGREES CELSIUS (194 DEGREES FAHRENHEIT) OR LOWER. Serious damage will occur if engine oil temperature exceeds the limit. It is solely customer’s responsibility to control the temperature.
- Installation of parts or accessories not originally equipped on products, including DAYTONA UPGRADE KIT PARTS, designed for top competition riders.
- Abnormal strain, neglect, or abuse.
- Accident or collision damage.
- Modification to original parts.
- Lack of proper maintenance.
- Damage due to improper transportation or use.
THE CUSTOMER’S RESPONSIBILITY
THE CUSTOMER’S RESPONSIBILITY:
- Operate and maintain products as specified in the appropriate Owner’s Manual.
CUSTOMER SERVICE
If products require services, you must take them to an authorized dealer, appointed by authorized local distributors of DAYTONA. DAYTONA Corp. JAPAN is NOT in the position to take care of services of any kind with the customers or authorized dealers due to the contract with authorized local distributors.
GENERAL SPECIFICATIONS
| ENGINE | |
|---|---|
| Engine Weight (Dry) | 18.0 kg |
| Engine type | Air Cooled 4-stroke SOHC |
| Cylinder arrangement | Single cylinder, Horizontally mounted |
| Displacement | 149.78 cm³ |
| Bore x Stroke | 57.0 × 58.7 mm (2.244 × 2.311 in) |
| Compression Ratio | 12.5 : 1 |
| Starting System | Kick (Kick pedal is NOT included in the Engine Kit) |
| Lubrication System | Wet sump |
| Recommended Engine Oil | SAE 10W-40 or higher grade |
| API "SG" or higher grade | |
| Engine Oil Capacity | |
| Periodic oil change | 0.60 L |
| With oil filter replacement Total amount | 0.65 L |
| 0.70 L | |
| Spark Plug | * Need more amount of oil when oil cooler is in use |
| Type/Manufacturer | |
| CR8HSA/NGK (resistance type) | |
| Gap | 0.7 ~ 0.8 mm (0.028 ~ 0.031 in) |
| Clutch type | Wet, Multi-plate 5-disc |
| Transmission | |
| Primary Reduction System | Gear |
| Primary Reduction Ratio | 67/18 (3.722) |
| Transmission Type | 4-Speed / (DT150BS type) |
| Gear Ratio | (Counter / Main) |
| 1st | 34/13 (2.6153) |
| 2nd | 29/17 (1.7058) |
| 3rd | 26/20 (1.3000) |
| 4th | 24/23 (1.0434) |
| GEAR SHIFT PATTERN | N-1-2-3-4 |
| Electrical | |
| Ignition System | AC-CDI |
| Generator System | AC magneto |
MAINTENANCE SPECIFICATIONS
| Item | Standard | Limit |
|---|---|---|
| Cylinder Head | ||
| Warp Limit | 0.05 mm (0.002 in) | |
| Cylinder: Bore size Out of round limit | 57.00 - 57.015mm (2.2441 - 2.2445 in) | 0.05 mm (0.002 in) |
| Camshaft: Drive method Cam dimensions | Chain drive (Left) | |
| A 8 Intake “A” “B" Exhaust “A” “B” | ||
| 26.49 - 26.61 mm (1.04291 - 1.0476 in) | ||
| 26.23 ~ 26.35 mm (1.0326 ~ 1.0374 in) 1.0192 in | 26.15 mm (1.0295 in) 25.89 mm | |
| Timing Chain: | ||
| Timing Chain No. of links | 88 link | 0.050 mm (0.0019 in) |
| Timing Chain Adjustment Method | Automatic | |
| Valve, Valve Seat, Valve Guide: | ||
| Valve Clearance (cold) IN EX | 0.05 ~ 0.07 mm (0.0020 ~ 0.0028 in) | |
| Valve Dimensions: "A" Head Diameter IN EX | 27.9 ~ 28.1 mm (1.0984 ~ 1.1062 in) | |
| 23.4 ~ 23.6 mm (0.8897 ~ 0.9291 in) | ||
| "B" Face Width IN EX | 0.8 ~ 1.0 mm (0.0314 ~ 0.03937 in) | |
| "C" Seat Width IN EX | 0.05 ~ 0.07 mm (0.0020 ~ 0.0028 in) | |
| "D" Margin Thickness IN EX | 0.8 ~ 1.0 mm (0.0314 ~ 0.03937 in) | |
| Stem Outside Diameter IN EX | 4.970 ~ 4.985 mm(0.19566 ~ 0.1962 in) | |
| 4.970 ~ 4.985 mm(0.19566 ~ 0.1962 in) | ||
| Stem-to-guide clearance IN EX: 0.015 ~ 0.042 mm(0.0005 ~ 0.0016 in) | ||
| Valve Spring: | ||
| Free Length IN /OUTER(Φ 22.4) | 34.12 mm (1.3433 in) | |
| /INNER(Φ 16.1) EX /OUTER(Φ 22.4) | 31.96 mm (1.2582 in) | |
| Piston: | ||
| Piston to Cylinder Clearance | 0.01~ 0.04 mm (0.00039 ~ 0.00157 in) | |
| Piston Size “D" H Measuring Point “H" Piston Off-set | 56.975 ~ 56.99 mm (2.2431 ~ 2.2437 in) | |
| Piston Pin Bore Inside Diameter | 13.002 ~ 13.008 mm (0.5118 ~ 0.5121 in) | |
| Piston Pin Outside Diameter | 12.995 ~12.998 mm (0.5116 ~ 0.5117 in) | |
| Piston Rings: Top Ring: | 0.8 × 2.25 mm (0.06 × 0.09 in) | |
| Dimensions (B × T) | End gap (installed) 0.05 ~ 0.20 mm (0.006 ~ 0.010 in) | |
| Side Clearance (installed) | 0.015 ~ 0.045 mm(0.0012 ~ 0.0026 in) | |
| Crankshaft: Crank Width “A" | 40.2 mm (1.58267 in) | |
| Runout Limit "C" | 0.03 (one-side) | 0.1 mm (0.0039 in) |
| Big End Side Clearance “D" | 0.1 ~ 0.35 mm (0.0039 ~ 0.0137 in) | |
| Small End Free Play "F" | 0.1 mm (0.0039 in) | |
| Clutch: Friction Plate Thickness Quantity | 2.9 ~ 3.1 mm (0.114 ~ 0.122 in) 5 | 2.7 mm (0.106 in) |
| Clutch Plate Thickness Quantity | 0.9 ~ 1.0 mm (0.043 ~ 0.051 in) 4 | 0.7 mm (0.0275 in) |
| Clutch Spring Free Length Quantity | 30.2 mm (1.1889 in) 4 | 0.2 mm (0.0787 in) 27.2 mm (1.0705 in) |
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice, or a race, make sure the engine is in good operating condition. Before using this engine, check the following points.
ENGINE OIL LEVEL INSPECTION
- Start the engine, warm it up for several minutes, and then turn off the engine and wait for a few minutes.
- Place the bike on a level place and hold it upright.
- Check the oil level through the sight glass. The oil level should be between the upper and the red-colored central point of the sight glass.
- Add oil to the proper level.
CARBURETOR SETTING
The carburetor is extremely sensitive to foreign matter (dirt, sand, water, etc.). During installation, do not allow foreign matter to get into the carburetor. Always handle the carburetor and its components carefully. Even slight scratches, bends, or damage to carburetor parts may prevent the carburetor from functioning correctly. Carefully perform all servicing with the appropriate tools and without applying excessive force. After installing the carburetor, check that the throttle operates 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 conditions and carburetor settings
| Air Temp. | Humidity | Air Pressure (Altitude) | Mixture | Setting |
|---|---|---|---|---|
| High | High | Low (High) | Richer | Leaner |
| Low | Low | High (Low) | Leaner | Richer |
The air density (i.e., concentration of oxygen in the air) determines the richness or leanness of the air/fuel mixture. Therefore, refer to the above table for mixture settings.
- Higher temperature expands the air with its resultant reduced density.
- Higher humidity reduces the amount of oxygen in the air due to water vapor. Lower atmospheric pressure (at a high altitude) reduces the density of the air.
EFFECTS OF THE SETTING PARTS ON THE THROTTLE VALVE OPENING
- Slow Jet / Pilot Screw
- Throttle valve cutaway
- Jet Needle / Needle Jet
- Main Jet
Here is the recommended setting information for KEIHIN PE28 carburetor:
| Tested Conditions | |
|---|---|
| Carburetor | KEIHIN PE28 |
| Air Temperature | 20 degrees Celsius |
| Humidity | 50% |
| Atmospheric Pressure | 1000 hPa |
| Item | Recommendation |
|---|---|
| Main Jet | #122-#125 (with AIR FILTER) / #130-#132 (without Air Filter) |
| Slow Jet | #38 (STD) |
| Throttle Valve | #3.0 |
| Jet Needle | #JFN (STD) Clip position: In the 1st groove from the top |
| Air Screw | 1 + 1/2 return |
IGNITION TIMING SELECTION
DAYTONA 150E ENGINE comes with an ignition timing selectable CDI unit.
Notes
- Timing (1) gives more torque at low-middle RPM levels.
- Timing (2) gives more torque at higher RPM levels than Timing (1).
Example (How to select)
- To select Timing (2), connect White and Green wires.
ENGINE OIL TEMPERATURE CONTROL
WARNING
Engine oil temperature is to be strictly controlled at 90 degrees Celsius (194 degrees Fahrenheit) or lower. Serious damage will occur in the engine if engine oil temperature exceeds 90 degrees Celsius or 194 degrees Fahrenheit. It is solely the customer’s responsibility to control the engine oil temperature. Any failures caused by overheating are NOT considered as defects of the products. It is highly recommended to use a HIGH-EFFICIENT OIL COOLER and OIL TEMPERATURE GAUGE to protect the engine.
The above OIL COOLER is just a recommendation. Engine oil temperature can be heated up over 90 degrees Celsius or 194 degrees Fahrenheit, even if the recommended OIL COOLER is used. Again, customers need to control the oil temperature very carefully.
OPTIONAL PARTS
OIL COOLER
The following oil coolers are available from Daytona, but the mount bracket must be made by the customer to fit on their bike. The kit components are shown in the photo below.
- Daytona Part# 61785
- Daytona Part# 62759
7-Core Oil Cooler Kit 10-Core Oil Cooler Kit (The same kit components as #61785.)
OIL TEMPERATURE GAUGE & FITTING
The following 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# 47101
- Daytona Part# 43350
Temp. gauge & sensor, 0-150 degrees Celsius PT1/8 (Tapered Thread)-Sensor fitting Sensor fitting for PT1/8 (Tapered Thread) sensor designed for 8mm inner diameter oil hoses.
DAYTONA 150E engine exploded view
The document 'DAYTONA 150E' is available for download below