Instruction Manual for KEIHIN PC18 Carburetor Kit
Contents
1. Item Nos Applicable models and Frame Nos Carburetor kit 6V DAX50 ST50 1000001 Manifold set except for 6800022 6346265 6V DAX 70 ST70 1000001 12VDAX J AB26 1000001 O Thank you for purchasing one of our TAKEGAWA s products Please strictly follow the following instructions in installing and using the products Before fitting the products please be sure to check the contents of the kit Should you have any questions about the products please kindly contact your dealer Please note that in some cases the illustrations and photos may vary from the actual hardware Please read the following instructions carefully before installation We do not take any responsibility for any accident or damage whatsoever arising from the use of the products not in conformity with the instructions in the manual We shall be held free from any kind of warranty whatsoever of products other than this product if the glitch takes place on the other products than this one after the installation and use of this product If you make alterations to the product we shall be held free from any guarantee of the product You are kindly requested not to contact us about the combination of our products with other manufacturers For installation of this Kit on a 6V motorcycle a high throttle set is additionally required A standard air cleaner cannot be equipped together with this product The engine will go2. screw exI0 S 11 Carburetor s initial settings Ot fomm washes T Ut Fuel hose o T Ot Hose clips 0 ort Main jet s Ot 5mm hex spanner 0 Throttle val ve x marks indicate the contents of a Air screw openi ng manifold kit ee Nov 08 08 Installation Procedure Please check the contents of this kit Installation Preparation CAUTION Be sure to tighten to the specified torque with a torque wrench A CAUTION Make sure that the engine and the muffler are cold enough Stabilize the vehicle 1 Install the fuel cock stay to the fuel cock with an M6x10mm socket cap screw midium and a 6mm washer Specified torque 10 N m 1 0 kgf m X Since the fuel cock will be detatched the fuel in the tank should be as little as possible before installation 1 After making sure that the fuel cock is closed open a drain cock on the carburetor and drain the gasoline from the float chamber to a tray or something 2 Unfasten a pan screw and detach the fuel cock from the carburetor PE Insert a collar to the threaded hole in which the air cleaner mounting bolt was fixed and install a fuel cock stay with a 6x15 mm socket cap screw s and a 6 mm washer s Specified torque 10 N m 1 0 kgf m G 3 Remove the top cap 2 Pull out the fuel tubes and reconnect them being careful of the oil leak The fuel tube with vartical lines is the one for reserve tank side X If
3. the tubes shows an indication of exhaustion such as wear out and crazings replace them with new ones HOU Unscrew the air cleaner mounting bolt s and the inlet pipe mounting bolt s and remove the carburetor with the inlet pipe attached Xx Be careful not to let any foreign materials fall into the intake port 4 Remove the air cleaner mounting bolt s and nut s and take out the air cleaner case from the frame 3 Temporarily attach the throttle cable to the under throttle housing and connect the inner cable with the throttle pipe 5 Unscrew the pan screw s on the throttle housing and take out the throttle cable Xx Be sure to keep the throttle housing and pan screw s for re use 4 After applying grease to the sliding surface of the throttle install the throttle housing Then tighten the pan screws Specified torque 8 N m 0 8 kgf m 6 Keep those removed parts in a bag or the like Wipe off dirts and old grease torque 8 N m 0 8 kgf m 5 Detatch the top cover of the kit s carburetor and remove the throttle valve spring and the throttle valve AL oh a Ne oe Nov 08 08 6 Place the carburetor gasket between 12 Pull the choke lever to start the engine and check each section for intake the carburetor and the inlet pipe and leak Gradually pushing the lever back warm up the engine till the fix it with two M6x20mm socket cap revolution becomes s
4. ck and carburetor and attach two hose clips Open the fuel cock and check each section for oil leaks Do not leave the j y cock open for a long time SPECIAL PARTS Co Ltd 3 5 16 Nishikiorihigashi Tondabayashi Osaka Japan TEL 81 721 25 1357 FAX 81 721 24 5059 URL http www takegawa co jp amp lt 3 Nov 08 f How to Set the Carburetor O When the carburetor does not match the engine and the engine fails the engine failures are caused by either too dense or too lean air fuel mixture O The engine failure symptoms for the engine are as follows When the air fuel mixture is too dense When the air fuel mixture is too lean O The explosion sound with a dull thud continues intermittently The engine overheats somewhat O The engine malfunctions further if you use the choke O The engine starts working well If you use the choke O The engine malfunctions when you warm it up O The engine does not accelerate well No smooth acceleration The engine works well if the cleaner is detached O Revolutions change generating weak power The motorcycle belches dense or black exhaust gas O The plug burns white O The plug smolders getting blackened X Set the carburetor only after warming up the engine and then test drive And use a plug with the right heat value x Do the setting in the following manner studying at what throttle opening position the engine starts
5. ct to change without prior notice This manual should be retained for future reference N
6. failing Jet needle Throttle position at 1 4 3 4 Whether or not the engine revolution is in proportion to the throttle operation O When the acceleration is not smooth or even make the air fuel mixture dense O Make the air fuel mixture lean when the engine revolution goes up heavily and belches black gas The mixture ratio at this throttle position can be adjusted by the location of E ring in the grooves The air fuel mixture becomes dense as the location of the E ring moves down from the 1st to the 5th groove 3rd groove 2nd groove 4th groove 1st groove oth groove Main jet The throttle position at 3 4 4 4 The air fuel mixture ratio at this throttle position can be adjusted by changing the number of the main jet The larger the main jet numbers the denser the mixture ratio becomes In view of the engine and muffler specifications select the most appropriate main jet to get the highest revolutions O Pilot jet First of all please adjust the air screw In case you have given more than three turns to the air screw to tighten it use a pilot jet with a small number O If you have tighten the air screw clockwise to the full use a pilot jet with a larger number Check whether you have made a right choice of the pilot jet by seeing if the engine starts up revolving smoothly from the idling to running at slow speed When the engine revolves up unevenly the pilot jet number is too small At idle O When the motorcyc
7. le belches black exhaust gas and produces heavy exhaust sound the pilot jet number is too big At idle O After replacing the pilot jet you need to readjust the airscrew O Air screw The air screw adjusts the air mass flow at the time of engine s revolving at slow speed At idling O Give the air screw a right turn The air fuel mixture gets dense O Give the air screw a left turn gt The air fuel mixture gets lean Loosen the tightened air screw back to the 1 5 turn position And then from this position give to the airscrew a right or left turn of 1 4 to 1 2 till the engine revolves at the highest speed Loosen the idle stop screw till you get the steady idling revolutions And once again adjust the position of the airscrew to get the highest revolutions On how the barometric pressure temperatures and humidity affect the setting At highlands or at high altitudes the barometric pressure and air density go down and the air gets into the carburetor in less amounts This makes the air fuel mixture dense which was adjusted at low altitudes Under the weather conditions with very low temperatures the air density increases which makes the air fuel mixture lean Under the rainy and humid weather conditions the air density decreases which makes the air fuel mixture dense Please be informed that mainly because of improvement in performance design changes and cost increase the product specifications and prices are subje
8. mooth And then push the lever back into the original screws and two 6 mm lock nuts location If the motorcycle does not run idle or it runs idle at high revolution Specified torque 10 N m after warming up adjust the revolution with the throttle stop screw 1 0 kgf m f D 13 Do settings in a safe place according to the specification of your vehicle with enough care N Drag the throttle cable up to the carburetor but not by sheer force Attach the carburetor top to the throttle cable and connect the inner cable with the throttle valve while compressing the throttle valve spring 8 Align the notch on the throttle valve in the direction of the throttle stop screw and then install it to the carburetor Notch Throttle stop screw 9 Place the inlet pipe gasket between the cylinder head and the inlet pipe and fix it with 6x25 mm socket cap screw s Specified torque 10 N m 1 0 kgf m gt E 10 Adjust the free play at the throttle grip to be about 5 mm by turning the adjuster of the throttle cable See the figure below Snap the throttle several times to make sure that the throttle moves smoothly without sticking and also to check that the valve is fully open X Also check that the throttle has free play even when the steering handle is turned all the way to the right or to the left _ Abo ut 5 mm iE 11 After adjusting the length of the fuel hose insert it into the fuel co
9. re riding always check every section for oil leak and slack in parts like screws Besides when you notice something abnormal with your motorcycle while riding down a road stop riding immediately and park your motorcyle in a safe place to check Otherwise the abnormaility could lead to an accident Always drive the engine in a well ventilated place and do not switch the engine on in an airtight place Otherwise you will suffer from carbon monoxide poisoning Before doing work place the motorcycle on level ground to stablize the position of your motorcycle for safety s sake Otherwise your motorcycle could fall down and injure you while you are working O As gasoline is highly flammable never place it close to fire Make sure that nothing flammable is near the gasoline Since vaporized accumulation of gasoline is at the high risk of explosion work in a well ventilated place Please be informed that mainly because of improvement in performance design changes and cost increase the product specifications and prices are subject to change without prior notice This manual should be retained for future reference Kit Contents B Pes ay No Parts Names Oy 1 Carburetor assembly 1 RO mepe T Carburetor ge 1 inlet pipe gaske T S e 1 z Socket cap screws 620 S 1 Socket cap screws 605 11 RO rue cock SS z0 _ Fuel_cock stay 0 Oo collar cae Uo Socket cap screw xis 11 Crt Socket cap
10. wrong if the engine gets wet So please refrain from running in the rain Besides before washing your vehicle cover the carburetor with a plastic sheet or the like to prevent water from getting into the carburetor The carburetor of this Kit is shipped at the basic setting Setting should be adjusted according to parts to be used Re set the carburetor to meet your engine Be sure to do the work referring to the right HONDA genuine parts service manual for the above mentioned applicable model The following show the envisioned possibility of injuries and damages to human bodies and property loss as a result of disregarding A CAUTION the following cautions Always use a torque wrench to screw bolts and nuts tight and securely to the specified torque Improper torque could cause these parts to get damaged or fall off O Work only when the engine and the muffler are cool at below 35 degrees C Otherwise you will burn yourself Prepare right tools for the work and do the work in the proper and right way Otherwise improper work could cause breakage of parts or injuries to yourself AN The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the WARNING following cautions O Those who are technically unskilled or inexperienced are required not to do the work Improper installation could lead to a driver s falling down or accidents as a result of parts breakage O Befo
Download Pdf Manuals
Related Search