Automotive Manual PDF

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.
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This kit is intended for use on 1993 and newer XR/CRF100’s using CDI ignition. Engine assembly requires special attention to detail. A new BBR Cylinder and piston kit have been supplied. The following measurments are critical to proper installation and performance.
Ring end gap: .012″ - .015″
Valve clearance: Intake: .002″ Exhaust: .003″
Piston to head clearance: .040″
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Installing the cab skirts: Remove any mud guards or stepping bars from the truck. Open the door on the truck and hold the cab side skirt in place. Secure the front part of the side skirt in the wheel well with the factory screw from the mud guard, then close the door and check to see that you have about a ¼” door gap between the bottom of the door and the side skirt. While holding the side skirt in place open the door and with a 1/8” drill bit, drill through the existing holes in the side skirt. Then secure the side skirt with the screws supplied in the hardware packet. While holding the rear portion of the cab side skirt in place drill a 1/8” hole through the side skirt and into the rocker panel and secure it with the screw supplied in the hardware packet as shown in fig.A. We have supplied you with two braces to secure the lower portion of the side skirt, install them evenly apart as shown in fig.B
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Removal
1. On the upper boost tube, loosen the hose clamp on the intercooler side using a 11mm socket and pull the silicone tube away from the intercooler.
2. Loosen both hose clamps for the bottom boost tube using a 11mm socket and remove the factory silicone hose from the boost tube and intercooler.
3. Using a 10mm socket, remove the two bolts that secure the factory oil cooler to the intercooler and the vehicle’s frame. One of the bolts is located on the top of the cooler, securing it to the factory intercooler, and the second is on the bottom of the oil cooler, securing it to the frame of the vehicle.
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Step 1:
Locate the points along the pole where your car door would make contact (typically these points would be the door handle, the apex of the door, and down near the lower frame of the door). If two vehicles are parked side-by- side, you may want to take into consideration where the second vehicle door makes contact with the pole as well. This will offer the maximum product effectiveness and economy. Slight adjustment and arrangement will usually allow for mutually good ring location for both vehicles. However, in rare situations such as large variations in vehicle height (i.e. Corvette and Ford Excursion) it may be necessary to purchase additional bumper rings to properly protect the vehicles.
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Headlamp guard
Installation
1 - Open the bonnet
- Clean the headlamp lens
- Take the mounting strips for the headlamp guards from the kit
- Pry up the weatherstrip for the headlamp. Use a plastic weatherstrip tool
- Insert the mounting strip between the top of the headlamp and the weatherstrip. Position the mounting strip as illustrated. (more…)

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We are pleased to confirm the initial marketing vehicle that each dealership will receive is currently in transit from the factory. We anticipate delivery of these vehicles to all dealerships beginning in late June within a minimum gap between individual dealer arrivals. These cars are configured to best showcase the vehicle, and will allow you to maximize test-drives and pre-sales opportunities. All vehicles are Highline 2.0 140HP TDI with automatic transmission in Reflex Silver Metallic on Anthracite Vienna leather. They are outfitted with ESP, Sirius Satellite Radio, and Rear Side Airbags.
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TECHNICAL INFORMATION
Spark Output: The Enhancer Ignition System for the Honda 400EX produces a high output spark that is approximately double the stock spark output. This increased spark energy allows the use of richer fuel mixtures or even exotic fuel such as alcohol. The MSD Ignition will put out approximately 30,000 volts to the spark plug.
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