Instruction Manual for KEIHIN PD22 Carburetor Kit
Contents
1. S Instruction Manual for KEIHIN PD22 Carburetor Kit For exclusive use with R Stage amp Regular Head Item No 03 05 111 Carburetor kit 03 02 035 Manifold kit Fit Monkey Frame Nos Z50J 1300017 Fit Gorilla Frame Nos Z50J 1300027 Fit Monkey BAJA FrameNos Z50J 17000010 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 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 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 A stock air cleaner cannot be installed with this Carburetor Kit The engine will go wrong if the engine gets wet So2. lia Installation Please check the contents of this kit Preparation CAUTION Make sure that the engine and the muffler are cold enough Stabilize the vehicle O Oin the case of the Gorilla and Monkey BAJA demount the seat and drain the gasoline in the fuel tank Close the fuel cock pull out the fuel hose from the carburetor and demount the fuel tank O O 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 O DUnfasten the inlet pipe holding bolt and air cleaner mounting bolt and detach the throttle valve from the carburetor Demount the carburetor with all the air cleaner box and inlet pipe attached to it x Be careful not to let any foreign material get into the intake port O O Unfasten the throttle valve from the carburetor Sepia the throttle valve from the throttle cable And remove the top cover from the throttle cable O O Unfasten the pan screws on the throttle housing to disconnect the throttle cable Wipe off dirt and worn out grease x Be careful not to lose the throttle housing or pan screws for reuse O O Fix the ground wire to the frame with the air cleaner mounting bolt O O Keep those detached parts in a bag or the like Installation CAUTION Be sure to tighten to the specified torque with a torque wren
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4. 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 it The supplied carburetor is factory preset as described at the bottom of this page As the setting should be adjusted according to the parts used reset the carburetor to match your engine Do the installation work correctly referring to Honda s genuine service manual for the above mentioned applicable models AY The following show the envisioned possibility of injuries to human bodies or property damages as a result of disregarding the following Caution 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 resulting in accidents 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 The following show the envisioned possibility of human death or serious 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 could lead to a driver s falling down or accidents as a result of parts breakage Q Before riding always check every sectio
5. 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 subject to change without prior notice This manual should be retained for future reference
6. 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 motorcycle belches black exhaust gas and produces heavy exhaust sound the pilot jet number is too big At
7. Adjust the setting to meet the motorcycle in a safe place with utmost care SPECIAL PARTS WwNSeYWA 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 r 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
8. ch connect the inner cable with the throttle pipe O0 O After applying grease to the sliding surface of the throttle install the throttle housing Then tighten the pan screws Torque 8 N m 0 8 kgf m O0 O Remove the float chamber from the PD22 carburetor and replace the main and slow jets with those of the Kit O O Reinstall the float chamber in its original Float syi woe position th aa A OY i es a ee chamber O Remove a top cover from the PD22 carburetor and pull out the throttle valve spring and the throttle valve O0 O Temporarily attach the throttle cable to the under throttle housing and Ne A Procedure O O Place the carburetor gaskets between carburetor and inlet pipe and tighten them to the specified torque with two M6x25 socket cap screws and two lock nuts Torque 10 N m 1 0 kgf m O0 O Run the supplied throttle cable up to the carburetor without stretching it too tight Connect the throttle cable to the carburetor top And connect the inner cable to the throttle valve while compressing the throttle valve spring Notch c gt le Throttle stop screw O iMesh the notch on the throttle valve with the throttle stop screw and install it to the carburetor O0 O Place the inlet pipe gaskets between cylinder head and inlet pipe and tighten them to the specified torque wi
9. n 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 No Pane Oy ne flock ne 6mm De Socket cap screw 6x70__ 1 To Soe cap screw 625 2 x marks indicate the contents of a manifold kit Factory preset mode of the carburetor 0 95 0 35 E2051G Clip position 4th from the top Throttle valve 74B Air screw opening 1 1 4 ais Feb 04 09
10. th two M6x20 socket cap screws Torque 10 N m 1 0 kgf m x In some cases the carburetor and frame interfere with each other because of the margin of error in the frame sizes In this case please cut off the interfering portions O0 O O Adjust the free play at the throttle grip to be about 5 mm with 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 X Also check that the throttle has free play even when a steering handle is turned all the way to the right and left O O D If the fuel tank is removed install and tighten a new fuel cock to the specified torque of 5 6N Jm 0 5 0 6 kgfm and reinstall the fuel tank and mount the seat O0 O O Adjust the fuel cock direction and the fuel tube length then insert the fuel tube into the fuel cock and the carburetor and attach the tube clip onto the fuel tube Open the fuel cock and check every part for oil leak Do not leave the cock open for long hours O0 O Pull the choke lever to start the engine and check every hardware for intake air leak Gradually release the lever and warm up the engine till the revolution becomes smooth and finally release the lever fully back to its original position In case after the warm up of the engine the engine does not run idle or idles away at high speed adjust the setting with the throttle stop screw O0 O O
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