DAYTONA

ANIMA 190SZ(SGL) ENGINE

Owner's Manual

ENGINE No. ANIMA190SZ: 3338577727-

corp.

0
 INTRODUCTION
Thank you for purchasing of a ANIMA Engine.
This manual explains operation, inspection, basic maintenance 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 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 on
public space is also illegal.
Please check local regulation before use.
2. This engine is to be used by EXPERIENCED RIDERS 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 and maintenance, 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 SERVICE

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.

(3) Abnormal strain, neglect, or abuse
(4) Accident or collision damage
(5) Modification to original parts
(6) Lack of proper maintenance
(7) Damage 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
(2) Prohibit the modification of the product

CUSTOMER SERVICE
If Products require services, you must take it to the authorized dealer, who is 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.

2
 CONTENTS
INTRODUCTION Page 1

CUSTOMER’S RESPONSIBILITY & CUSTOMER SERVICE Page 2

CONTENTS Page 3

PART NAMES Page 4

GENERAL SPECIFICATIONS Page 5

MAINTENANCE SPECIFICATIONS Page 6 – 9

MAINTENANCE INTERVALS Page 10 - 12

PRE-OPERATION INSPECTION AND MAINTENANCE Page 13 - 19

ENGINE OIL LEVEL INSPECTION Page 13
CARBURETOR SETTING Page 14 - 16
IGNITION TIMING SELECTION Page 17
REV LIMITER SELECTION Page 18
ENGINE OIL TEMPERATURE CONTROL Page 19

ELECTRICAL DIAGRAM Page 20

TIGHTENING TORQUE Page 21

3
PART NAMES

4
 GENERAL SPECIFICATIONS

ENGINE
Engine Weight (Dry) 22.0 kg
Engine type Air Cooled 4-stroke SOHC
Cylinder arrangement Single cylinder, Horizontally mounted
Displacement 189.9 cm3
Bore × stroke 66. 0× 55.5mm
Compression ratio 12.0 : 1
Starting system Kick (Kick pedal is NOT included in the Engine Kit)
With Decompression System
Lubrication system Wet sump
Recommended Engine Oil SAE 10W - 40 or higher grade
API “SG” or higher grade
Engine oil capacity
Periodic oil change 0.65 L
With oil filter replacement 0.70 L
Total amount 0.75 L
* Need more amount of oil when oil cooler is in use
Spark plug
Type/manufacturer ER9EH / NGK (resistance type)
Gap 0.6 ~ 0.7 mm (0.024 ~ 0.028 in)
Clutch type Wet, Multi-plate 6-disc

Transmission
Primary reduction system Gear
Primary reduction ratio 67/18 (3.722)
Transmission type 5-Speed
Gear ratio (Counter / Main)
1st 34/14 (2.4285)
2nd 26/15 (1.7333)
3rd 24/18 (1.3333)
4th 24/22 (1.0909)
5th 22/24 (0.9166)
GEAR SHIFT PATTERN 1-N-2-3-4-5
Electrical
Ignition system AC-CDI
Generator system AC magneto

5
 MAINTENANCE SPECIFICATIONS

Item Standard Limit

Cylinder head 0.05 mm
Warp limit ---- (0.002 in)

Cylinder:
Bore size 66.00 - 66.015mm (2.5984 – 2.599) ----
Out of round limit ---- 0.05 mm
(0.002 in)
Camshaft:
Drive method Chain drive (Left) ----
Cam dimensions

Intake “H” 30.18 ~ 30.30 mm 29.84 mm

(1.1882 ~ 1.1929 in) (1.1748 in)
“D” ---- ----
---- ----
Exhaust “H” 30.21 ~ 30.33 mm 29.87 mm
(1.1894 ~ 1.1941 in) (1.1760 in)
“D” ---- ----
---- ----

6
 MAINTENANCE SPECIFICATIONS

Item Standard Limit

Timing chain:
Timing chain No. of links 94 link ----
Timing chain adjustment
method Automatic ----
Valve, valve seat, valve guide:
Valve clearance (cold) IN 0.05 ~ 0.07 mm (0.0020~ 0.0028 in) ----
0.05 ~ 0.07 mm (0.0020~ 0.0028 in)
EX ----

Valve dimensions:

“A” head diameter IN 24.4 ~ 24.6 mm (0.9606 ~ 0.9685 in) ----

EX 20.9 ~ 21.1 mm (0.8228 ~ 0.8307 in) ----
“B” face width IN --- ----
EX --- ----
“C” seat width IN 0.8 ~ 1.0 mm (0.0314 ~ 0.03937 in) 1.6 mm (0.0630 in)
EX 0.8 ~ 1.0 mm (0.0314 ~ 0.03937 in) 1.6 mm (0.0630 in)
“D” margin thickness IN ---- ----
EX ---- ----
Stem outside diameter IN 4.470 ~ 4.485 mm(0.17598 ~ 0.1766 in) 4.42 mm (0.1740 in)
EX 4.470 ~ 4.485 mm(0.17598 ~ 0.1766 in) 4.42 mm (0.1740 in)
Guide inside diameter IN 4.500 ~ 4.512 mm(0.17716 ~ 0.1776 in) 4.55 mm(0.1791 in)
EX 4.500 ~ 4.512 mm(0.17716 ~ 0.1776 in) 4.55 mm(0.1791 in)
Stem-to-guide clearance IN 0.015 ~ 0.042 mm(0.0005 ~ 0.0016 in) 0.08 mm(0.003 in)
EX 0.03 ~ 0.057 mm(0.0011 ~ 0.0022 in) 0.10 mm(0.004 in)

Valve spring:
Free length
IN (φ16.2) 42.59 mm(1.6767 in) 40.38 mm(1.5897 in)
EX (φ16.2) 42.59 mm(1.6767 in) 40.38 mm(1.5897 in)

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 MAINTENANCE SPECIFICATIONS

Item Standard Limit

Piston:
Piston to cylinder clearance 0.01 ~ 0.04 mm 0.1mm(0.004 in)
(0.00039 ~ 0.00157in)
Piston size “D” 65.975 ~ 65.99 mm ----
(2.5974 ~ 2.598 in)

Measuring point “H” 8 mm (0.31 in) ----

Piston off-set ---- ----
Piston pin bore inside 14.002 ~ 14.013 mm 14.06 mm
diameter (0.5513 ~ 0.5517 in) (0.5535 in)
Piston pin outside diameter 13.995 ~ 13.998 mm 13.97 mm
(0.5510 ~ 0.5511 in) (0.55 in)
Piston rings:

Top ring:
Dimensions (H × W) 0.8 × 2.25 mm (0.06 × 0.09 in)
End gap (installed) 0.05 ~ 0.20 mm (0.006 ~ 0.010 in) 0.4 mm (0.020 in)
Side clearance (installed) 0.015 ~ 0.045 mm(0.0012 ~ 0.0026in) 0.10 mm (0.005 in)

2nd ring:

Dimensions (H × W) 0.8 × 2.25 mm (0.06 × 0.09 in)

End gap (installed) 0.05 ~ 0.20 mm (0.006 ~ 0.010 in) 0.4 mm (0.031 in)
Side clearance 0.015 ~ 0.045 mm(0.0012 ~ 0.0026in) 0.10 mm (0.005 in)

Oil ring:
Dimensions (H × W) 1.50 × 2.25 mm (0.06 × 0.09 in) ----
End gap (installed) 0.2 ~ 0.7 mm (0.004 ~ 0.016 in) 0.9 mm (0.005 in)

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 MAINTENANCE SPECIFICATIONS

Item Standard Limit

Crankshaft:
Crank width “A” 42.2 mm (1.66142 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) 0.6 mm (0.0236 in)
Small end free play “E” ----

Clutch:
Friction plate thickness 2.9 ~ 3.1 mm (0.114 ~ 0.122 in) 2.7 mm (0.106 in)
Quantity 6 ----
Clutch plate thickness 1.4 ~ 1.5 mm (0.055 ~ 0.059 in) 1.2 mm (0.0472 in)
Quantity 5 ----
Warp limit ---- 0.2 mm (0.0787 in)
Clutch spring free length ---- ----
Quantity 4 ----

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 MAINTENANCE INTERVALS

Item After Every Every Every As Remarks

break- race third fifth requir
in (or 500 (or 1,000 ed
(50km) km) km)
ENGINE OIL
Replace ● ●
Inspect ●
ENGINE VALVES The engine must
Check the valve ● ● be cold.
clearances Check the valve
Inspect ● seats and valve
Replace ● stems for wear.

VALVE SPRINGS Check the free

Inspect ● length and the tilt.
Replace ●
CAMSHAFTS Inspect the
Inspect ● camshaft surface.
Replace ●
TIMING CHAIN Check for wear on
SPROCKETS, TIMING the teeth and for
CHAIN ● damage.
Inspect ●
Replace
PISTON Inspect crack
Inspect ● ● Inspect carbon
Clean ● deposits and
Replace ● eliminate them.

10
 MAINTENANCE INTERVALS

Item After Every Every Every As Remarks

break- race third fifth requir
in (or 500 (or 1,000 e-ed
(50km) km) km)
PISTON RING Check ring end
Inspect ● gap
Replace ● ●
PISTON PIN
Inspect ●
Replace ●
CYLINDER HEAD Inspect carbon
Inspect and clean ● deposits and
Replace ● eliminate them.
Change gasket
CYLINDER Inspect score
Inspect and clean ● marks
Replace ● Inspect wear
CLUTCH Inspect housing,
Inspect and adjust ● ● friction plate,
Replace ● clutch plate and
spring
TRANSMISSION Inspect wear of
Inspect ● gear and bearings
Replace ●

SHIFT FORK, SHIFT Inspect wear

CAM, GUIDE BAR
Inspect ●
Replace ●
ROTOR NUT
Retighten ● ●
CRANK
Inspect and align ● ●
CARBURETOR
Inspect, adjust, clean ● ●

11
 MAINTENANCE INTERVALS

Item After Every Every Every As Remarks

break- race third fifth requir
in (or 500 (or 1,000 e-ed
(50km) km) km)
SPARK PLUG
Inspect and clean ● ●
Replace ●
OIL COOLING
SYSTEM(Option)
Check hoses & ● ●
leakage
Replace hoses and ●
gaskets
AIR FILTER (Option) Use foam air-filter
Clean and lubricate ● ● oil or equivalent oil
Replace ●
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 LEVEL 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.).
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 Mixture Setting

(Altitude)
High High Low Richer Leaner
(High)
Low Low High Leaner Richer
(Low)
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.

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 PRE-OPERATION INSPECTION AND MAINTENANCE
Effects of the setting parts on the throttle valve opening

(1)

(2)

(3)

(4)

Closed 1/8 1/4 1/2 3/4 Full

Open
(1) Slow Jet / Pilot Screw
(2) Throttle valve cutaway
(3) Jet Needle / Needle Jet
(4) Main Jet

Here is the recommended setting information of TK MV33-1F and PE28 carburetor,

for your reference.

Tested Conditions
Carburetor TK MV33-1F (DT#88600)
Air Temperature 35 degrees Celsius
Humidity 50%
Atmospheric Pressure 1003 hPa
with UNI Air Filter (#UP-4200ST)
Fuel Octane#100

Item Recommendation
Main Jet #129
Slow Jet #38
Main No φ2.600
Jet Needle 5A11
Clip position : In the 5th groove from the top
Pilot screw 2 return

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 PRE-OPERATION INSPECTION AND MAINTENANCE

Carburetor KEIHIN PE28 (DT#85707)

Air Temperature 20 degrees Celsius
Humidity 50%
Atmospheric Pressure 1000 hPa
with UNI Air Filter (#UP-4200ST)
Fuel Octane#100

Item Recommendation
Main Jet #122 (DT#87004)
Slow Jet #38 (DT#89672)
Throttle Valve #3.0
(Original of DT#85707)
Jet Needle #65414 / 46JFQ (-2 / φ2.505)
or
46JFN : Original of KEIHIN PE28 (DT#85707)

Clip position : In the 2nd or 3rd groove from the top

Air screw 2 return

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 PRE-OPERATION INSPECTION AND MAINTENANCE

IGNITION TIMING SELECTION

ANIMA FDX/FLX ENGINE comes with ignition timing selectable CDI unit.

To change the ignition timing, it needs to change the connection of the wires that come out
of the CDI unit.
WIRE CONNECTION TABLE

Color of Wire WHITE GREEN YELLOW GREEN INGITION TIMING

Timing (1) REDUSE

Timing (2)

Timing (3)

Timing (4) ADVANCE

WARNING
USE ADVANCE TIMING GIVES HIGH TEMPERATURE TO ENGINE.
SERIOUS DAMAGE WILL OCCURE IN THE ENGINE BY ABNORMAL COMBUSTION.
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.

Example (How to select)

* To select Timing (2), connect Yellow and Green wires.

17
 PRE-OPERATION INSPECTION AND MAINTENANCE

REV LIMITER SELECTION

ANIMA FDX/FLX ENGINE comes with rev limiter selectable CDI unit.

To change the rev limiter, it needs to change the connection of the wires that come out of the
CDI unit.
WIRE CONNECTION TABLE

BLACK/
Color of Wire BLUE GREEN
YELLOW
Rev Limiter (1)
-11,500rpm
Rev Limiter (2)
-12,200rpm
Rev Limiter (3)
-12,900rpm

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.

19
ELECTRICAL DIAGRAM for SZ

20
 TIGHTENING TORQUE

Standard
Size Tightening Torque Size Tightening Torque
N.m (kgf.m) N.m (kgf.m)
5mm Bolt, Nut 5.2 (0.5) 5mm Screw 4.2 (0.4)

6mm Bolt, Nut 10 (1.0) 6mm Screw 9.0 (0.9)

8mm Bolt, Nut 22 (2.2) 6mm Screw (Small Flange) 10 (1.0)
10mm Bolt, Nut 34 (3.5) 6mm Screw (Large Flange) 12 (1.2)
12mm Bolt, Nut 54 (5.5) 8mm Flange Bolt, Nut 27 (2.8)

10mm Flange Bolt, Nut 39 (4.0)

Others
Nut M8, Cylinder Head : 22N.m (2.2kgf.m)
Nut M14, Clutch center and Primary Gear : 44N.m (4.5kgf.m)
Nut M12, Magnet Rotor : 59N.m (6.0kgf.m)
Bolt M12, Oil Drain : 24N.m (2.4kgf.m)

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corp.
2022.01.25