Instruction Manual for KEIHIN PE24 Carburetor Kit
Contents
1. N Item No 0 O0 0 0 0 0 0 0 Paper type filter 0 0 0 0 0 0 0O O O Sponge type filter Fits Frame Nos CRF50F AE03 1400001 XR50R_ AE03 10000 1 O We are flattered that you have purchased one of TAKEGAWA s products Please strictly follow the following instructions in installing and using the products O 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 do read the following 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 responsibility or compensation whatsoever for any glitch in the parts other than ours if the glitch takes place after the installation and use of thse products The installation of the products entails machining of a stopper on the throttle pipe And please note that with the machining an accelerator limiter will get unavailable Do the installation work correctly referring to Honda s genuine service manual for the above mentioned applicable models This kit is designed for exclusive use in the above mentioned applicable models and frame numbers only Please take note that this kit cannot be m2. 1 the air cleaner stay and two bolts on the manifold and then detach a manifold carburetor and air cleaner Attach an earth cable to the frame with the bolt on the air cleaner stay Earth cable AN Ps Unscrew a bolt on the storage tank and pull out a breather hose from the crankcase Storage tank _ _ gt Z F Feb 04 09 Detachment of Throttle Cable Loosen a hex nut on the throttle cable lt Unfasten two screws and detach a throttle housing and throttle pipe from the handle Detach a stock throttle cable from the lower throttle housing Attachment of Throttle Cable lt Machine the stopper on the throttle pipe to remove it Stopper gt Attach a throttle cable of the kit to the lower throttle housing Connect an inner cable to the machined throttle pipe and fix the throttle housing to the handle with two screws Tighten hex nuts on the throttle cable Attachment of Carburetor Place a gasket between cylinder head and inlet pipe and tighten the gasket with socket cap screws Fix firmly the insulator into the inlet pipe with a socket cap screw Torque 10 N m 1 0 kgf m Insulator Screws 6x15 Ze D Carburetor Screws 6x20 Gasket Place the carburetoe into the insulator and tighten the band to secure it lt Remove the top cap from the carburetor and detach the spring needle clip retai
3. A 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 Feb 04 09 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 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
4. 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 subject to change without prior notice This manual should be retained for future reference N
5. d place 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 w This manual should be retained for future reference A A Feb 04 09 UU Throttle valve Cut way Air screw opening gasoline from the float chamber Detachment of Exterior Parts Bolt a fuel tank XK ENA OY ae SS War B PEZ WH Factory preset mode of the carburetor Main jet Slow jet J et needle Clip position 48 36S 3rd from the top 1SC 3 0 1 1 2 Installation Procedures Make sure your bike is secure on level ground for safety s sake Carburetor Detachment Shut off a fuel cock and open a drain cock on the carburetor to drain First detach from the carburetor a top cap hose of a storage tank bolt on First detach two trim clips two screws and two bolts and then detach an assembly of a seat shroud and rear fender Bolts Washer Collar 7 yy Cy Sye Y AW ay T T si Fuel tank i as os Detach a fuel hose from the carburetor and detach two bolts to demount Kit Contents w rne OF Ca sem ooo a 6 Socket cap screw 620 2 e Thote cable nomm 1 9 Fue tank front spacer 30mm
6. 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 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
7. ner and throttle valve Attach to the throttle cable the top cap spring throttle valve and then the needle clip retainer Attach the throttle valve to the carburetor aligning the notch with the throttle stop screw Snap the throttle a few times to check how much the throttle valve opens and closes Attach and fix an airfilter by fastening a band Adjust the free play at the throttle grip to be about 5 mm with an adjuster on the throttle cable You are requested to dispose of the blow by gas from the crankcase by yourself For example Attach the storage tank so the air filter does not interfere with the tank and let the blow by gas into the air filter with a breather hose of the kit O Attachment of Exterior Parts Put a front tank spacer between the front fuel tank and frame and attach a bolt And put a rear tank spacer between the rear fuel tank and frame and attach the collar and kit s washer and fasten the bolt Bolt 8x40 a Bolt 8x55 Stock collar Lf Front tank spacer Put a prong on the back of the seat into a hook on the frame and attach an assembly of seat shroud rear fender with two each of trim clips screws and bolts Xx Pulling the shroud align the mounting hole with a threaded screw hole in the fuel tank and fit two screws into the holes In case it s hard to fit the screws elongate the holes with a rasp and the like st SPECIAL PARTS WN4SeYWZ
8. ounted on other types of motorcycles If you make modifications to the products we shall be held free from any guarantee of the products You are kindly requested not to contact us about the combination of our products with other manufacturers Setting of a carburetor needs to be adjusted depending on the natural phenomena like the weather temperatures and motorcycles and carburetors 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 The following show the envisioned possibility of injuries to human bodies or property damages as a result of disregarding the Caution following cautions O Work only when the engine and the muffler are cool Otherwise you will burn yourself Prepare right tools for the work Otherwise the installation with improper tools could cause breakage of parts or injuries to yourself 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 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 Or improper torque may cause pa
9. rts to come off Always use new gaskets and packings And check those parts to be reused for wear and damage If you find wear or damage replace them with new ones Warning The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the following cautions O Always start the engine in a well ventilated place and do not turn the engine on in an airtight place Otherwise you will suffer from carbon monoxide poisoning When you notice something abnormal with your motorcycle while riding down a road stop riding immediately and park your motorcyle in a safe place Otherwise the abnormality could lead to accidents Before doing work secure the motorcycle 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 parts correctly according to the procedures in the instruction manual or a service manual Improper checking or maintenance could lead to accidents O If you find damaged parts when checking and performing maintenance 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 ventilate
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