Daytona Anima 190F User manual

DAYTONA
ANIMA 190F ENGINE
Owner's Manual
ANIMA 190F
--- Four-Valve Head Engine ---
ENGLISH MANUAL SECTION Page 2 - 25
PARTS CATALOGUE SECTION Page 26 - 36
CATALOGUE ES PIECES ATACHEES Page 26 - 36
corp.

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INTRODUCTION
Thank you for purchasing of a ANIMA 190f 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. ANIMA 150f ENGINE is designed strictly FOR COMPETITION USE, ONLY ON A
CLOSE 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 EXPERIENCE RI ERS 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.

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CUSTOMER’S RESPONSIBILITY & CUSTOMER SER ICE
GENERAL EXCLUSIONS
Any failures caused by the following reasons are NOT considered as the defects of
Products.
(1) Overheating due to improper engine oil temp. control
WARNING
ENGINE OIL TEMPERATURE MUST BE 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 customer’s responsibility to control the engine oil
temperature.
(2) Installation of parts or accessories that is not originally equipped on Products.
This includes AYTONA UPGRA E KIT PARTS as well, since those are designed for
the top competition riders.
(3) Abnormal strain, neglect, or abuse
(4) Accident or collision damage
(5) Modification to original parts
(6) Lack of proper maintenance
(7) amage due to improper transportation or use
THE CUSTOMER’S RESPONSIBILITY
THE CUSTOMER’S RESPONSIBILITY shall be :
(1) Operate and maintain Products as specified in the appropriate Owner’s Manual
CUSTOMER SER ICE
If Products require services, you must take it to the authorized dealer, who is appointed by
authorized local distributors of AYTONA.
AYTONA 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.

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CONTENTS
INTRO UCTION Page 2
CUSTOMER’S RESPONSIBILITY & CUSTOMER SERVICE Page 3
CONTENTS Page 4
PART NAMES Page 5
GENERAL SPECIFICATIONS Page 6
MAINTENANCE SPECIFICATIONS Page 7 – 10
MAINTENANCE INTERVALS Page 11 - 13
PRE-OPERATION INSPECTION AN MAINTENANCE Page 14
ENGINE OIL LEVEL INSPECTION Page 14
CARBURETOR SETTING Page 15 - 17
IGNITION TIMING SELECTION Page 18
REV LIMITER SELECTION Page 19
ENGINE OIL TEMPERATURE CONTROL Page 20
ELECTRICAL IAGRAM Page 21
OPTIONAL PARTS Page 22 - 25
PARTS CATALOGUE Page 26 – 36

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PART NAMES

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GENERAL SPECIFICATIONS
ENGINE
Engine Weight ( ry)
Engine type
Cylinder arrangement
isplacement (ANIMA150f)
Bore × stroke (ANIMA150f)
Compression ratio
Starting system
21.5 kg
Air Cooled 4-stroke SOHC
Single cylinder, Horizontally mounted
187.18 cm3
62.0 × 62.0 mm (2.441 × 2.441 in)
12.1 : 1
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
With oil filter replacement
Total amount
0.60 L
0.65 L
0.70 L
* Need more amount of oil when oil cooler is in use
Spark plug
Type/manufacturer
Gap
ER9EH / NGK (resistance type)
0.6 ~ 0.7 mm (0.024 ~ 0.028 in)
Clutch type Wet, Multi-plate 6-disc
Transmission
Primary reduction system
Primary reduction ratio
Transmission type
Gear ratio
1st
2nd
3rd
4th
GEAR SHIFT PATTERN
Gear
67/18 (3.722)
4-Speed
(Counter / Main)
34/13 (2.6153)
26/15 (1.7333)
25/21 (1.1904)
22/24 (0.9166)
N-1-2-3-4
Electrical
Ignition system
Generator system
AC-C I
AC magneto

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MAINTENANCE SPECIFICATIONS
Item Standard Limit
Cylinder head
Warp limit
----
0.05 mm
(0.002 in)
Cylinder:
Bore size
Out of round limit
62.00 - 62.015mm (2.4409 – 2.4415)
----
----
0.05 mm
(0.002 in)
Camshaft:
rive method
Cam dimensions
Intake “H”
“ ”
Exhaust “H”
“ ”
Chain drive (Left)
30.18 ~ 30.30 mm
(1.1882 ~ 1.1929 in)
----
----
30.21 ~ 30.33 mm
(1.1894 ~ 1.1941 in)
----
----
----
29.84 mm
(1.1748 in)
----
----
29.87 mm
(1.1760 in)
----
----

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MAINTENANCE SPECIFICATIONS
Item Standard Limit
Timing chain:
Timing chain No. of links
Timing chain adjustment
method
94 link
Automatic
----
----
Valve, valve seat, valve guide:
Valve clearance (cold) IN
EX
0.05 ~ 0.07 mm (0.0020~ 0.0028 in)
0.05 ~ 0.07 mm (0.0020~ 0.0028 in)
----
----
Valve dimensions:
“A” head diameter IN
EX
“B” face width IN
EX
“C” seat width IN
EX
“ ” margin thickness IN
EX
Stem outside diameter IN
EX
Guide inside diameter IN
EX
Stem-to-guide clearance IN
EX
24.4 ~ 24.6 mm (0.9606 ~ 0.9685 in)
20.9 ~ 21.1 mm (0.8228 ~ 0.8307 in)
---
---
0.8 ~ 1.0 mm (0.0314 ~ 0.03937 in)
0.8 ~ 1.0 mm (0.0314 ~ 0.03937 in)
----
----
4.470 ~ 4.485 mm(0.17598 ~ 0.1766 in)
4.470 ~ 4.485 mm(0.17598 ~ 0.1766 in)
4.500 ~ 4.512 mm(0.17716 ~ 0.1776 in)
4.500 ~ 4.512 mm(0.17716 ~ 0.1776 in)
0.015 ~ 0.042 mm(0.0005 ~ 0.0016 in)
0.03 ~ 0.057 mm(0.0011 ~ 0.0022 in)
----
----
----
----
1.6 mm (0.0630 in)
1.6 mm (0.0630 in)
----
----
4.42 mm (0.1740 in)
4.42 mm (0.1740 in)
4.55 mm(0.1791 in)
4.55 mm(0.1791 in)
0.08 mm(0.003 in)
0.10 mm(0.004 in)
Valve spring:
Free length
IN (φ16.2)
EX (φ16.2)
42.59 mm(1.6767 in)
42.59 mm(1.6767 in)
40.38 mm(1.5897 in)
40.38 mm(1.5897 in)

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MAINTENANCE SPECIFICATIONS
Item Standard Limit
Piston:
Piston to cylinder clearance
Piston size “ ”
Measuring point “H”
Piston off-set
Piston pin bore inside
diameter
Piston pin outside diameter
0.01 ~ 0.04 mm
(0.00039 ~ 0.00157in)
61.975 ~ 61.99 mm
(2.4399 ~ 2.4405 in)
8 mm (0.31 in)
----
14.002 ~ 14.013 mm
(0.5513 ~ 0.5517 in)
13.995 ~ 13.998 mm
(0.5510 ~ 0.5511 in)
0.1mm(0.004 in)
----
----
----
14.06 mm
(0.5535 in)
13.97 mm
(0.55 in)
Piston rings:
Top ring:
imensions (H × W)
End gap (installed)
Side clearance (installed)
2nd ring:
imensions (H × W)
End gap (installed)
Side clearance
Oil ring:
imensions (H × W)
End gap (installed)
0.8 × 2.25 mm (0.06 × 0.09 in)
0.05 ~ 0.20 mm (0.006 ~ 0.010 in)
0.015 ~ 0.045 mm(0.0012 ~ 0.0026in)
0.8 × 2.25 mm (0.06 × 0.09 in)
0.05 ~ 0.20 mm (0.006 ~ 0.010 in)
0.015 ~ 0.045 mm(0.0012 ~ 0.0026in)
1.50 × 2.25 mm (0.06 × 0.09 in)
0.2 ~ 0.7 mm (0.004 ~ 0.016 in)
0.4 mm (0.020 in)
0.10 mm (0.005 in)
0.4 mm (0.031 in)
0.10 mm (0.005 in)
----
0.9 mm (0.005 in)

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MAINTENANCE SPECIFICATIONS
Item Standard Limit
Crankshaft:
Crank width “A”
Runout limit “C”
Big end side clearance “ ”
Small end free play “E”
42.2 mm (1.66142 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 spring free length
Quantity
2.9 ~ 3.1 mm (0.114 ~ 0.122 in)
6
0.9 ~ 1.0 mm (0.043 ~ 0.051 in)
5
----
----
4
2.7 mm (0.106 in)
----
0.7 mm (0.0275 in)
----
0.2 mm (0.0787 in)
----
----

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MAINTENANCE INTER ALS
Item After
break-
in
(50km)
Every
race
Every
third
(or 500
km)
Every
fifth
(or 1,000
km)
As
requir
ed
Remarks
ENGINE OIL
Replace
Inspect
● ●
●
ENGINE VALVES
Check 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
Replace
●
●
Inspect the
camshaft surface.
TIMING CHAIN
SPROCKETS, TIMING
CHAIN
Inspect
Replace
●
●
Check for wear on
the teeth and for
damage.
PISTON
Inspect
Clean
Replace
● ●
●
●
Inspect crack
Inspect carbon
deposits and
eliminate them.

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MAINTENANCE INTER ALS
Item After
break-
in
(50km)
Every
race
Every
third
(or 500
km)
Every
fifth
(or 1,000
km)
As
requir
e-ed
Remarks
PISTON RING
Inspect
Replace
●
● ●
Check ring end
gap
PISTON PIN
Inspect
Replace
●
●
CYLIN ER HEA
Inspect and clean
Replace
●
●
Inspect carbon
deposits and
eliminate them.
Change gasket
CYLIN ER
Inspect and clean
Replace
●
●
Inspect score
marks
Inspect wear
CLUTCH
Inspect and adjust
Replace
● ●
●
Inspect housing,
friction plate,
clutch plate and
spring
TRANSMISSION
Inspect
Replace
●
●
Inspect wear of
gear and bearings
SHIFT FORK, SHIFT
CAM, GUI E BAR
Inspect
Replace
●
●
Inspect wear
ROTOR NUT
Retighten
● ●
CRANK
Inspect and align
● ●
CARBURETOR
Inspect, adjust, clean
● ●

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MAINTENANCE INTER ALS
Item After
break-
in
(50km)
Every
race
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)
Clean and lubricate
Replace
● ●
●
Use foam air-filter
oil or equivalent oil
OIL FILTER
Replace
● ●
OIL STRAINER
Clean
●

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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 LE EL 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 level place and hold it up on upright position.
3. Check the oil level through the sight glass.
Oil level should be between the upper and the central point of the sight glass.
4. Add oil to proper level
WARNING
Add oil as necessary, when install the oil cooler.

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PRE-OPERATION INSPECTION AND MAINTENANCE
CARBURETOR SETTING
The carburetor is extremely sensitive to foreign matter (dirt, sand, water, etc.).
uring 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
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.
That is:
 Higher temperature expands the air with its resultant reduced density.
 Higher humidity reduces the amount of oxygen in the air by so much of the water vapor
in the same air.
 Lower atmospheric pressure (at a high altitude) reduces the density of the air.
Air Temp. Humidity Air Pressure
(Altitude)
Mixture Setting
High High Low
(High)
Richer Leaner
Low Low High
(Low)
Leaner Richer

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PRE-OPERATION INSPECTION AND MAINTENANCE
Effects of the setting parts on the throttle valve opening
(1) Slow Jet / Pilot Screw
(2) Throttle valve cutaway
(3) Jet Needle / Needle Jet
(4) Main Jet
(1)
(2)
(3)
1/8 1/4
Closed 1/2 3/4 Full Open
Here is the recommended setting information of KEIHIN PWK33 and PE28 carburetor,
for your reference.
Tested Conditions
Carburetor KEIHIN PWK33
Air Temperature 20 degrees Celsius
Humidity 50%
Atmospheric Pressure 1000 hPa
Item Recommendation
Main Jet #125(with UNI Air Filter)
Slow Jet #42
Throttle Valve
#6.0
Jet Needle #86590 W956R-1175W( AYTONA original)
#86640 W956R-1171N
Clip position : In the 2nd or 3rd groove from the top
Air screw 2 return

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PRE-OPERATION INSPECTION AND MAINTENANCE
Carburetor KEIHIN PE28
Air Temperature 20 degrees Celsius
Humidity 50%
Atmospheric Pressure 1000 hPa
Item Recommendation
Main Jet #125(with UNI Air Filter)
Slow Jet #42
Throttle Valve
#3.0
Jet Needle #69414 / 46JFQ (-2 / φ2.505)
Clip position : In the 3rd groove from the top
Air screw 2 return

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PRE-OPERATION INSPECTION AND MAINTENANCE
IGNITION TIMING SELECTION
ANIMA 190f ENGINE comes with ignition timing selectable C I unit.
To change the ignition timing, it needs to change the connection of the wires that come out
of the C I unit.
WIRE CONNECTION TABLE
Color of Wire
Color of WireColor of Wire
Color of Wire WHITE
WHITEWHITE
WHITE GREEN
GREENGREEN
GREEN YELLOW
YELLOWYELLOW
YELLOW GREEN
GREENGREEN
GREEN INGITION TIMING
INGITION TIMINGINGITION TIMING
INGITION TIMING
Timing (1) REDUSE
REDUSEREDUSE
REDUSE
Timing (2)
Timing (3)
Timing (4) ADVANCE
ADVANCEADVANCE
ADVANCE
Notes
NotesNotes
Notes
(a) Reduce Timing gives more torque at low-middle rpm level.
(b) Advance Timing gives more torque at higher rpm level than the Reduce Timing.
WARNING
WARNING WARNING
WARNING
USE ADVANCE TIMING GIVES HIGH TEMPERATURE TO ENGINE.
SERIOUS DAMAGE WILL OCCURE IN THE ENGINE BY ABNORMAL COMBUSTION.
Example (How to select)
* To select Timing (2), connect Yellow and Green wires.

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PRE-OPERATION INSPECTION AND MAINTENANCE
RE LIMITER SELECTION
ANIMA 190f ENGINE comes with rev limiter selectable C I unit.
To change the rev limiter, it needs to change the connection of the wires that come out of the
C I unit.
WIRE CONNECTION TABLE
Color of Wire
Color of WireColor of Wire
Color of Wire BLUE
BLUEBLUE
BLUE GREEN
GREENGREEN
GREEN BLACK/
BLACK/BLACK/
BLACK/
YELLOW
YELLOWYELLOW
YELLOW GREEN
GREENGREEN
GREEN GREEN/
GREEN/GREEN/
GREEN/
WHITE
WHITEWHITE
WHITE
Rev Limiter (1)
Rev Limiter (1)Rev Limiter (1)
Rev Limiter (1)
-11,500rpm
-11,500rpm-11,500rpm
-11,500rpm
Rev Limiter (2)
Rev Limiter (2)Rev Limiter (2)
Rev Limiter (2)
-12,200rpm
-12,200rpm-12,200rpm
-12,200rpm
Rev Limiter (3)
Rev Limiter (3)Rev Limiter (3)
Rev Limiter (3)
-12,900rpm
-12,900rpm-12,900rpm
-12,900rpm
Rev Limiter (4)
Rev Limiter (4)Rev Limiter (4)
Rev Limiter (4)
-13,600rpm
-13,600rpm-13,600rpm
-13,600rpm
Rev Limiter (5)
Rev Limiter (5)Rev Limiter (5)
Rev Limiter (5)
-15,000rpm
-15,000rpm-15,000rpm
-15,000rpm
Example (How to select)
* To select Rev Limiter (3)-12,900rpm, connect Blue and Green wires.

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PRE-OPERATION INSPECTION AND MAINTENANCE
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 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 to use 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 above recommended OIL COOLER is used.
Again, customer needs to control the oil temperature very carefully.