Instruction Manual for Big Carburetor Kit, VM26, for CRF150F

Instruction Manual for Big Carburetor Kit, VM26, for CRF150F
Instruction Manual for
Big Carburetor Kit, VM26, for CRF150F
CO
Item No. :03―05―333
Fits
:CRF150F (KPT)
Year
:From ‘02 to ’05
・Thank you for purchasing one of our TAKEGAWA-made products. Please strictly follow the following instructions in installing and using the Kit.
・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.
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 this
Instruction 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 supplied here, we shall be held free from any guarantee of the product.
◎ You are 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 models only and that it cannot be mounted on any other models.
◎ When ordering repair parts, please quote Item No. above and reference Nos in the figures in this Manual. Should you have any questions about the
Kit, please kindly contact your local motorcycle dealer.
◎Setting of a carburetor must be adjusted depending on the natural phenomena like the weather, temperatures and barometric pressure, and machine
and carburetor themselves. Arrange the setting to match the engine and other conditions.
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The following show the envisioned possibility of injuries to human bodies and property damage as a result of disregarding the
CAUTION following cautions.
・Work only when the engine and muffler are cool at below 35 degrees Celsius. Otherwise, you will get burned.
・Do the installation with right tools. (Otherwise, breakage of parts or injuries to you 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.)
・Before riding, always check every hardware like screws for slack. If you find slack ones, screw them securely up to the specified torque.
(Otherwise, improper tightening may cause parts to come off.)
The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the
WARNING following warnings.
・When you notice something abnormal with your motorcycle while riding, immediately stop riding and park your motorcycle in a safe place to check what has gone wrong. (Otherwise, the malfunction 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.)
・Check or carry out maintenance of your motorcycle correctly according to the procedures in the instruction manual or service manual.
(Improper checking or maintenance could lead to accidents.)
・If you find damaged parts when checking or 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 accidents.)
・Keep plastic bags for packing the products out of children's reach, or discard them.
(If children get them on, there will be a danger of their suffocating.)
・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.
Factory preset mode of the carburetor
Main jet
Pilot jet
Jet needle
Clip position
Throttle valve cut-away
Air screw opening
#190
#22.5
5E75
3rd from top
#1.5
1-1/4 turns backwards
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Mar./28/’
07
Kit includes:
1
9
CO
2
3
4
5
6
7
8
No.
1
2
3
4
5
6
7
8
9
Part Name
Carburetor unit (VM26)
Throttle cable
Insulator
Inlet pipe
Gasket
Hose clamp (for 30 ∼ 45 mm)
Hose clamp (for 32 ∼ 50 mm)
Socket cap screw, 6 x 15
Throttle valve spring
Qty
1
1
1
1
1
1
1
4
1
∼ Installation Instructions ∼
1.Make sure your vehicle is secure on a
maintenance stand or the like on level and safe ground.
2.Close a fuel cock and open the drain cock
on the carburetor to drain gasoline from the
float chamber onto an oil container. Then, detach the fuel hose from the carburetor.
3.Remove the seat and fuel tank from the
vehicle.
4.Remove a carburetor top cap, and
detach the throttle valve, with a throttle cable
attached, from the carburetor.
5.Separate the throttle valve, throttle cable
and carburetor top cap.
6.In order to replace the throttle cable with the
supplied one, unfasten two screws on the
throttle grip housing. And detach the existing
throttle cable from the throttle grip housing and remove the cable from the motorcycle.
※ We recommend you to write down how you
have routed the throttle cable and at which
angle you have installed the grip.
7. Fit a supplied throttle cable to the throttle housing, and route it in the same way as the
genuine cable is routed.
8.Loosen the clamp which is holding the
carburetor and air cleaner together.
And demount the existing carburetor with the
inlet pipe attached.
※ Be careful not to let any foreign material fall
into the intake port.
9.Place an inlet pipe gasket between cylinder
head and inlet pipe, and tighten the inlet pipe
with a supplied socket cap screw.
※ The front and rear surfaces of the gasket are not the same. Be careful, therefore, that
the port hole does not match cylinder head or
inlet pipe, if the gasket is placed inside out.
Torque: 10 N・m (1.0 kgf・m)
11.Remove the supplied carburetor top cap,
and pull out the spring and the throttle valve.
Fit the throttle cable into the rubber cable cap
of the carburetor. And pass the inner cable
through the carburetor top cap, and then the
spring as well. Compressing the spring,
attach it to the throttle valve.
※ Be sure to change to the supplied throttle spring.
16.Snap the throttle a few times to make sure
that the throttle moves smoothly without sticking and that the throttle valve is fully
open. And check that the throttle has free
play even when a steering handle is turned
all the way to the right or to the left.
17.Install the fuel tank to the vehicle, and
connect a fuel hose to the carburetor.
Open the fuel cock and check every
hardware for gasoline leak.
(Do not leave the cock open for many hours.)
PY
12.Align the notch on the throttle valve with the
throttle stop screw, and attach the throttle valve to the carburetor.
18.Detach a restrictor on the top of the air cleaner box. If it remains attached, the Big
Carburetor can not demonstrate its high performance.
13.First, fit the air cleaner box of the carburetor,
and fasten it with a 32-50mm hose clamp.
※If you find it hard to fit the box, fit it using a flat tip screwdriver. And position and tighten
the clamp as near as possible to the
carburetor.
14.Then, fit the carburetor into the insulator,
and fasten it with a 30-45mm hose clamp.
15.Adjust the free play at the throttle grip to be
about 5 mm by turning the adjuster of the throttle cable. After the adjustment, cover the
adjuster with a rubber adjuster cover.
19.Reinstall the seat back into its original
location.
20.Pull the choke lever to start the engine.
Gradually push the lever back and warm
up the engine till the revolutions become 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. 21.Adjust the setting with utmost care in a safe place to meet the specification of your
motorcycle.
Adjuster
Less free play
More free play
Co.,Ltd.
About 5 mm
3-5-16 Nishikiorihigashi Tondabayashi
Osaka Japan
10. Fasten the insulator to the inlet pipe with
two socket cap screws.
Torque: 10 N・m (1.0 kgf・m)
TEL : 81-721-25-1357 FAX : 81-721-24-5059
URL : http://www.takegawa.co.jp
-2-
Mar./28/’
07
CO
Warning
Warning
Please be informed as follows with regard to the supplied MIKUNI VM26 Carburetor:
A standard on-road throttle valve spring is incorporated into this VM26 carburetor at
Please be informed as follows with regard to the supplied MIKUNI VM26 Carburetor:
A standard on-road throttle valve spring is incorporated into this VM26 carburetor at
the factory.
the factory.
PY
In connecting the throttle wires, please be sure to replace the spring with the supplied off-road heavy-duty throttle valve spring.
In connecting the throttle wires, please be sure to replace the spring with the supplied off-road heavy-duty throttle valve spring.
This hard throttle valve spring serves to ease the malfunction triggered by the throttle
This hard throttle valve spring serves to ease the malfunction triggered by the throttle
closure caused by the mud and sand adhering to the throttle, throttle wires, throttle
valve and other hardware.
closure caused by the mud and sand adhering to the throttle, throttle wires, throttle
valve and other hardware.
However, please note that this does not go so far as to completely prevent the poor
However, please note that this does not go so far as to completely prevent the poor
return of the throttle caused by dirt. Therefore, before riding, inspect various parts,
and stop riding whenever you feel something abnormal when driving.
return of the throttle caused by dirt. Therefore, before riding, inspect various parts,
and stop riding whenever you feel something abnormal when driving.
return of the throttle caused by dirt. Therefore, before riding, inspect various parts,
and stop riding whenever you feel something abnormal when driving.
return of the throttle caused by dirt. Therefore, before riding, inspect various parts,
and stop riding whenever you feel something abnormal when driving.
However, please note that this does not go so far as to completely prevent the poor
However, please note that this does not go so far as to completely prevent the poor
valve and other hardware.
valve and other hardware.
closure caused by the mud and sand adhering to the throttle, throttle wires, throttle
closure caused by the mud and sand adhering to the throttle, throttle wires, throttle
plied off-road heavy-duty throttle valve spring.
This hard throttle valve spring serves to ease the malfunction triggered by the throttle
plied off-road heavy-duty throttle valve spring.
This hard throttle valve spring serves to ease the malfunction triggered by the throttle
In connecting the throttle wires, please be sure to replace the spring with the sup-
In connecting the throttle wires, please be sure to replace the spring with the sup-
A standard on-road throttle valve spring is incorporated into this VM26 carburetor at
the factory.
A standard on-road throttle valve spring is incorporated into this VM26 carburetor at
the factory.
Please be informed as follows with regard to the supplied MIKUNI VM26 Carburetor:
Please be informed as follows with regard to the supplied MIKUNI VM26 Carburetor:
Warning
Warning
How to Set the Carburetor
・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.
・The engine failure symptoms for the engine are as follows:
When the air-fuel mixture is too dense:
CO
When the air-fuel mixture is too lean:
・The explosion sound with a dull thud continues intermittently.
・The engine malfunctions further if you use the choke.
・The engine malfunctions when you warm it up.
・The engine overheats somewhat.
・The engine starts working well If you use the choke,.
・The engine does not accelerate well. (No smooth acceleration)
・The engine works well if the cleaner is detached.
・The motorcycle belches dense (or, black) exhaust gas.
・The plug smolders, getting blackened.
・Revolutions change, generating weak power.
・The plug burns white.
※ Set the carburetor only after warming up the engine, and then test-drive. And use a plug with the right heat value.
※ 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
・When the acceleration is not smooth or even, make the air-fuel mixture dense.
・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.
2段目
2nd groove
3段目
3rd
groove
4段目
4th
groove
1段目
1st
groove
○Main jet (The throttle position at 3/4 - 4/4)
PY
5段目
5th
groove
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.
○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.
・ 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)
・ When the motorcycle belches black exhaust gas and produces heavy exhaust sound, the pilot jet number is too big. (At idle)
・After replacing the pilot jet, you need to readjust the airscrew.
○ Air screw
The air screw adjusts the air mass flow at the time of engine’s revolving at slow speed. (At idling)
・Give the air screw a right turn → The air-fuel mixture gets dense.
・Give the air screw a left turn → 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.
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
Aug./20/’
09
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