KEIHIN PE24 Carburetor Kit Instruction Manual
Contents
1. end to the throttle valve SPECIAL PARTS WNASEYMM Co Ltd Manifold Carburetor 0 D Aligning the notch on the throttle valve with the 3 5 16 Nishikiorihigashi Tondabayashi throttle stop screw and attach the throttle valve Osaka Japan to the carburetor body And fasten the TEL 81 721 25 1357 FAX 81 721 24 5059 carburetor top URL http www takegawa co jp a L Connecting tube band screw Y 22 Dec 10 12 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 w2. N KEIHIN PE24 Carburetor Kit Instruction Manual Item No 0 O O 0 0 O 0 0 Carburetor Kit 0 0 0 0 0 00 0O Inlet pipe Kit Compatible with Dream50 Frame No AC15 1000001 Thank you for purchasing one of our products Please strictly follow the following instructions in installing and using the kit Before installing the kit please be sure to check the 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 Please read the following 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 If you make modifications to any product of the kit 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 Please note that this kit is designed for exclusive use in the above mentioned compatible model and frame numbers only and that it cannot be mounted on other models The following show the envisioned possibility of inju
3. contents of a Inlet pipu kit Muffler Megaphone muffler A 25 Dec 10 12 N I nstal ation Procedures O Check the kit contents O O Loosen the carburetor top to remove it O USnap the throttle a few times to make sure Prepare tools suitable for the work O O Compressing the throttle valve spring detach that the throttle moves smoothly without Warning Make sure that your the throttle cable from the throttle valve and sticking and that the throttle valve is fully open motorcycle is secure on level then the carburetor top from the throttle cable O Woining together the hook on the fuel tank and ground O O Place a gasoline container under the fuel tank mounting rubber on the frame mount carburetor float chamber Loosen the drain the fuel tank N Caution Check that the engine and muffler are cold Warning Gasoline is so inflammable screw on the carburetor to drain gasoline in the In order not to damage the fuel cock at the carburetor into the container bottom of the fuel tank raise the back of the Warning No Fire fuel tank off the ground O0 O OHang the fuel tank strap on the hook of the 1 O O Loosen a screw on the air screw connecting tube band and unfasten two M6 manifold mounting bolts on the engine side to remove the caburetor that never use fire in the work place And beware of fireworks as well as naked lights which may trigger electric sparks
4. ainly 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. frame and fix it firmly with a mounting bolt A Caution Be sure to tighten to the specified torque Torque 10 N m 1 0 kgf m Removal O O Turn off the fuel cock Air cleaner case O O Olnsert the fuel tube into the fuel cock on the fuel tank And cut the fuel tube to the proper length being careful not to break it Fuel tank strap Air cleaner connecting tube Connect the fuel tube to the carburetor and fix it with the insulation lock of the kit O O O Attach the fuel valve extension to the fuel valve and open the fuel cock to check every place for the oil leak After confirming that there is no oil leak Fuel tank Fuel valve extension NR S o tighten the screw and fix the fuel valve UU U Remove the air cleaner connecting tube on extension the air cleaner Case 0 O O Attach the left side cover O0 0O U Install the seat joining together the hooks i both on the seat and frame and fasten the Installation seat tightly with two flange bolts O O Fasten the insulator No 3 tightly to the inlet A Caution Be sure to tighten to the specified pipe No 2 of the kit with two socket cap screws torque O O Unfasten two flange bolts on the seat to remove the seat No 9 Torque 12 N j m 1 2 kgf m O O Untasten a screw on the left side cover to f4 Caution Be sure to tighten to the specified remove the cover torque O O Unfastsen a screw on the fuel valve ex
6. he instruction manual or service manual Improper checking or maintenance could lead to accidents 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 as they are could lead to an accident 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 Ke This manual should be retained for future reference yy qs Dec 10 12 f f T 10 N m 1 0 kgf m Kit Contents D Top cover Throttle valve l Spring Throttle stop screw mo Part Name oy o Carburetor assembly o epe S ni FI Ceo insutor OC 7 48 insulator an f 365 e ip posit 3rd groove from top a unner band Throtie valve 15C o Fome gasket Cutaway 30 eo fese ooo S Air screw opening 1 1 2 Socket cap screw a5 0 oife fo Engine Specification E Egne STD Insulation tock Too mm o Camshaft STD Ignition System Hyper CDI Toot rex wrench Sim fo marks indicate the
7. ious injuries to human bodies as a result of disregarding the WARNING following cautions Those who are technically unskilled or inexperienced are required not to do the work Improper installation because of insufficient skill and knowledge could lead to parts breakage and subsequenily to accidents 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 Never look into the carburetor s intake pipe when the engine is running Flames could spurt by the spitting back of gasoline or backfire which may cause burns loss of sight and injury O Before riding always check every section for slack in parts and oil leak If you find slack in screws and other parts screw them securely to the specified torque with a torque wrench Driving with loose parts may lead to parts coming off or to accidents And if you continue driving with gasoline leaking there is a possibility of vehicle fire When you notice something abnormal with your motorcycle while riding stop riding immediately and park your motorcyle in a safe place Otherwise the abnormality could lead to accidents Before doing work make sure your bike 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 t
8. ith 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 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 run
9. ning 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 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 m
10. ries to human bodies and property damage as a result of disregarding the following cautions O Work only when the engine and muffler are cool 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 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 O As this product has an air funnel it collects dust in the air more easily than an air cleaner and air filter Therefore regular maintenance is essential Otherwise the failure may cause engine damage Please refrain from driving in the rain as much as possible Driving in the rain may cause engine to get wet So be sure to perform the engine maintenance without fail Moisture in the engine may cause the engine to go wrong O When the engine is off do not leave the gasoline cock open for a long time There is a possibility of the gasoline overflowing AN The following show the envisioned possibility of human death or ser
11. tension to remove the extension Torque 10 N m 1 0 kgf m O O Disconnect the fuel tube from the fuel cock D Fasten the gasket No 8 and the inlet pipe No 2 O O Unfasten the fuel tank mounting bolt detach tightly to the cylinder head with two sockeg the fuel tank strap and then remove the fuel cap screws No 9 tank by holding its back up and pulling it backward A Caution Be sure to tighten to the specified torque O0 O O Pull the choke lever to start the 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 O0 O O Do the setting with the utmost care ina safe place Xx After demounting the fuel tank place the tank on a stable solid object like a block to prevent the damage to the fuel cock falling of the tank and gasoline leaks Torque 10 N m 1 0 kgf m O0 O Remove a carburetor top from the carburetor No 1 of the kit and attach the carburetor top to the throttle cable O O Wind the funnel gasket No 7 around the carburetor No 1 Attach the air funnel No 5 and fix it with the funnel band No 6 O Put the carburetor No 1 into the insulator No 3 a which please fix with the insulator band No 4 O O Attach the throttle valve spring to the throttle cable on the carburetor top And compressing the throttle valve spring attach the throttle cable
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