Instruction

INSTRUCTION FOR HOW TO REPLACE "GUIDE WHEEL ROLLER" - DAYTONA 150cc "T-Rex"
It will take approx. 5-10 minutes to replace the installation.
The guide roller shown on the left is the one that should be replaced, and the replacement guide roller is shown on the right.

The Guide Roller that should be replaced

has "SUN" and "MADE IN JAPAN" logos embossed The replacement Guide Roller
has "ZS" logo embossed

FIG.1 FIG.2 FIG.3

Loosen the bolt, which is on the right side of the Remove the cam-sprocket cover. Loosen the bolts to remove the leftside flywheel cover
cylinder head in orde to remove the cam-sprocket
cover on the left.

1 / 5 page
 Instruction

FIG.4 FIG.5 FIG.6

Align the marking of the crank case with the Be sure the marking on the cylinder head and the Loosen the two mounting bolts of the cam-sprocket.
marking(TDC marking) on the flywheel. marking on the cam-sprocket are aligned, also.

The Longer Marking Line

FIG.7 FIG.8 FIG.9

Remove the cam-sprocket by using a needle-nose plier Hook the cam chain on the camshaft housing Loosen the indicated bolt, so that the camchain
as below. guide roller(hereinafter called "the guide roller")
comes loose.

2 / 5 page
 Instruction

FIG.10 FIG.11 FIG.12

Use a L-shaped hexagon wrench with a diamter Continue to slide the guide roller leftward As you continue to slide leftward, you can see
of 3-4mm(0.118-0.157 inch) to slide the guide roller by using the L-shaped wrench the guide roller coming out of the triangle hole
leftward(the cylinder head side). where the cylinder head was attached.

FIG.13 FIG.14 FIG.15

Hold the upper side of the guide roller by using Then clutch the guide roller by using a needle-nose Have the replacement guide roller, and place it
a screw driver or a sort of stick, plier to pull it out. between the upper and lower camchains.
as the guide roller comes out. Discard the guide roller. (DO NOT USE IT AGAIN !) It is a little tight to place in the position.

3 / 5 page

FIG.16
Find the center hole of the guide roller by using the
L-shaped hexagon wrench.
And place it in the right position.
FIG.19
Place the cam-sprocket back to the original position.
Instruction
FIG.17
Have the guide roller fixing bolt with washer to
install the guide roller.
The bolt should be torqued to 10Nm(7.4ft-lbf).
FIG.20
Align the marking of the cylinder head with the marking
of the cam-sprocket by turning only the cam sprocket.
And then, hand tight the two M5 bolts to fix
the cam-sprocket temporarily.
DO NOT TURN CAM CHAIN with cam sprocket.
4 / 5 page
FIG.18
Loosen the bolt, which is on the leftside of the shift
shaft, to the halfway approx. 5 turns to release
the cam chain tension.
FIG.21
Be sure the marking of the crank case and the
marking(TDC marking) on the flywheel are aligned.
BOTH THE MARKINGS, FLYWHEEL SIDE(FIG.20)
AND CAM-SPROCKET SIDE(FIG.21),
MUST BE ALIGNED
Otherwise, the ignition timing becomes wrong.
The Longer Marking Line
 Instruction

FIG.22 FIG.23 HOLD THE FLYWEEL AND TURN THE CRANKSHAFT

TIghten the two bolts(M5) to fix the cam-sprocket. Tighten the bolt, which is on the leftside of the shift 1-2 TIMES, AND THEN DOUBLE CHECK BOTH THE
These two bolts should be torqued to 7.85Nm(5.8ft-lbf). shaft, to 10Nm(7.4ft-lbf). ALIGNMENT. SEE FIG.20 and FIG.22.

FIG.24
Install the flywheel cover and the cam sprocket cover again.
All the bolts should be torqued to 10Nm(7.4ft-lbf).

5 / 5 page