"service manual"
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1. MIKUNI VM26 Carburetor Kit Instruction Manual For exclusive use in the Super Head 4VALVE R equipped motorcycle Item No 0 0 0 0 0O 0 0 O Carburetor set 0 oO 0 0 0 0 000 Manifold kit Compatible Models and Frame No Monkey amp Gorilla Z50J 2000001 2699999 AB27 1000001 1899999 Monkey R L AB22 1000017 AKEGAWA made products Please strictly follow the following instructions in installing and using the kit Q Before installing the kit please be sure to check the kit contents Should you have any questions about the kit please contact your local motorcycle dealer Please note that in some cases the illustrations and photos may vary from the actual hardware Read all instructions first before starting the installation We do not take any responsibility for any accident or damage whatsoever arising from the use of the kit 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 This carburetor kit is for exclusive use in a motorcycle equipped with a TAKEGAWA made Super Head 4VALVE R Bore Up Kit and Bore Stroke Up Kit This kit is compatible only with a stock engine and Super Head 4VALVE R Do the installation work correctly referring to the relative Honda s genuine service manual fo2. Otherwise these parts may get damaged or fall off resulting in accidents AS some products and frames have sharp edges or protruding portions please work with your hands protected Otherwise you will suffer injuries O Before riding always check every section for slack in parts like screws If you find slack ones screw them securely up to the specified torque Otherwise improper tightening may cause parts to come off Always use new gaskets and seals And check those parts to be reused for wear and damage If you find worn or damaged parts replace them with new ones AN Warning N vars The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the Warning following cautions Always start the engine in a well ventilated place and do not turn on the engine in an airtight place Otherwise you will suffer from carbon monoxide poisoning O When you notice something abnormal with your motorcycle while riding immediately stop riding and park your motorcyle in a safe place to check what has gone wrong Otherwise the abnormality could lead to accidents Before doing work make sure your motorcycle is secure on level ground for safety s sake Otherwise your motorcycle could overturn and injure you while you are working O Check or carry out maintenance of your motorcycle correctly according to the procedures in the instruction manual or service manual Impr
3. 0mm Pa o apne o a e CaS mne As o CoO eposs fn EA E fos ors Tis pewensm ij Mo x Please note that in ordering repair parts be sure to quote the Repair Part Item No Otherwise we may not be able to accept your orders There are some parts however for which we are not in a position to accept your order in just the quantity to be used In this case please take them in the quantity packed VM26 Pilot J et VM26 Main J et yy 00 03 0153 15 00 03 0156 22 5 00 03 0157 25 00030158 0 05 0159 N carburetor 00 03 0061 105 00o 120 00 03 0065 125 00 03 0066 00 05 0067 00 03 0068 140 00 03 0075 175 00 03 0078 190 00 03 0079 195 00 03 0082 220 00 03 0085 250 00 03 0086 yx Setting of a carburetor must be adjusted depending on the natural phenomena like the weather temperatures and barometic pressure and machine and carburetor themselves Arrange the setting to match the engine and other conditions x A standard air cleaner cannot be installed to this carburetor kit Therefore the engine will go wrong if water gets into the engine and please refrain from driving 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 Zz ae Sep 30 11 Please check the kit contents Preparation for Installation A Caution Check that the engine and muffler are cool and that
4. Dispose of the blow by gas from the crankcase by yourself Some racing and regulations specify the blow by gas disposal In sending back the blow by gas to the carburetor connect the blow by hose with the union on the air filter O Pull the choke lever to startthe engine Gradually push the lever back and warm up the engine till the revolution becomes smooth and finally push the lever back to its original location In case the engine does not run idle after the warm up of the engine or the engine idling speed is high adjust the setting by turning the throttle stop screw Jetting and other set up with your engine specification please do this set up at safe and closed area such as racetrack SPECIAL PARTS Co Ltd 3 5 16 Nishikiorihigashi Tondabayashi TEL 81 721 25 1357 FAX 81 721 24 5059 URL http www takegawa co jp Osaka Japan A wy _4 Sep 30 11 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
5. crew 6x25 surface of the throttle pipe the cable end and to the portion on the pipe to take up the cable A Caution Apply the specified torque Torque 10 N m 1 0 kgf m A Caution Apply the specified torque Torque 5 N m 0 5 kgf m Loosen a band screw on the connecting tube of the carburetor unfasten two bolts and remove the air cleaner Remove a top cover of the supplied carburetor and pull out the spring and the throttle valve Pass the inner cable of the throttle cable through the carburetor top cover and then through the spring And compressing the spring fix the top cover to the throttle valve Fix the throttle valve to the carburetor by aligning a notch on the throttle valve with the throttle stop screw Attach a socket set screw packed in the Cylinder Head Kit in the case of the Moneky and Gorilla to two taps A and in the case of the Monkey R to two taps B on the cylinder head surface to which to attach the inlet pipe and tighten the screws to the specified torque A Caution Apply the specified torque Torque 5 N m 0 5 kgf m T O Remove a top cover from the carburetor O Unfasten two screws on the throttle cable holder and remove the throttle with the housing and all Throttle cable holder O Place an inlet pipe gasket between the cylinder head and the i
6. e 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 motorcycle 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 af
7. fect 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 subject to change without prior notice This manual should be retained for future reference N
8. nlet pipe and fix it by tightening 6x25 socket cap screws to the specified torque O Referring to the service manual demount the engine from the frame And with reference to the installation procedures for the Super Head 4VALVE R install the Super Head 4VALVE R to the engine and mount the engine onto the frame A Caution Apply the specified torque Fit the carburetor into the Torque 10 N m 1 0 kgf m insulator and fasten the carburetor with a clamp band i H CON A Caution Do follow the LAND instructions in the service manual Be sure to tighten to the S specified torque aee Sep 30 11 Va O Attach an air filter which please fix by tightening a band Adjust the free play at the throttle grip to be about 5 mm by turning the adjuster of the throttle cable Snap the throttle a few times to make sure that the throttle moves smoothly without sticking and that the throttle valve is fully open Xx Also check that the throttle has free play even when a steering handle is turned all the way to the right or to the left x In some case need to adjust the fuel cock mount angle Warning Care about torque when you tight fuel cock nut Over torque may damage sealing O Insert a fuel tube and fasten it with a tube clip Open the fuel cock and chock for gas leaks Do not leave the cock open for long time
9. oper checking or maintenance could lead to accidents O If you find damaged parts when checking and performing maintenance of your motorcycle do not use these parts any longer and replace them with new ones The continued use of these damaged parts could lead to accidents 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 high risk of explosion work in a well ventilated place Otherwise it may cause a fire 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 XK yy S sie Sep 30 11 N Kit Contents HA Ee a Optional part gt Throttle cable 710 mm W Fe Factory preset mode of the carburetor HU UU Main jet 190 5 Pilot jet 22 5 oo J et needle 5E75 UO Uv Clip position 3rd from top Throttle valve Air screw opening 1 5 1 1 4 tums ___ wo eaae O Part Name im packs of Ta Yinsultor bad 0 000050 E gt pemes S f0 05 0007 a e semo o o ooa 90 7 esw O o oo j o opaa Ya fs 00 S a 2S E Tio fTrvotie COMB E T Tair fwote cable 810m a osoxcat o Pair of throttle grips for right amp leftthand 1 09 02 0002 1 Tis Fuet hese 20
10. r the above mentioned compatible models Please note that this kit is designed for exclusive use in the above mentioned compatible models and frame numbers only and that it cannot be mounted on other models You are kindly requested not to contact us about the combination of our products with other manufacturers Setting of a carburetor must be adjusted depending on the natural phenomena like the weather temperatures and barometic pressure and machine and carburetor themselves Arrange the setting to match the engine and other conditions For your information the carburetor is shipped out in a state described on page 2 In installing this kit a stock throttle housing is not used Therefore a brake lever and others need to be prepared by the user This kit is designed for exclusive use in the closed racing So do not drive your motorcycle on a public road after the installation of this kit Drive your motorcycle at a legal speed abiding by the laws AN The following show the envisioned possibility of injuries to human bodies and property damage as a result of disregarding the Caution following cautions Make sure the engine and muffler are cool before starting the installation Otherwise you will burn yourself O Do the installation with right tools Otherwise breakage of parts or injuries to yourself may take place Always use a torque wrench to screw bolts and nuts tight and securely to the specified torque
11. the motorcycle is secure on level ground In the case of Monkey and Gorilla Making sure that the fuel cock is closed open a drain plug on the carburetor and drain the gasoline from the float chamber to a tray Unfasten the inlet pipe tightening bolt and air cleaner mounting bolts Remove a throttle valve from a carburetor Then remove the carburetor with the air cleaner box the inlet pipe and all A Le ae Remove the throttle valve from the carburetor and separate the throttle valve from the throttle cable Then pull out the top cover from the throttle cable Unfasten a pan screw on the throttle housing to remove the throttle housing Fix an ground wire to the frame with an air cleaner mounting bolt Installation Procedures In the case of Monkey R Installation In the case of Monkey R O Detach a seat turn the fuel cock O Pass the supplied throttle cable oer n l off detach a fuel tube from the through the frame a carburetor O Pass the supplied throttle cable unfasten a fuel cock mounting bolt through the lower throttle housing and a tank nut and remove the fuel and connect the inner cable to the tank throttle pipe And attach the throttle Screw 6x2 housing to the handle with two screws X Apply grease to the rubbing O Fasten the insulator to the inlet pipe with two socket cap screws Fuel tube S
12. 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 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 engin
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