Instruction Manual for KEIHIN PD22 Carburetor Kit
For exclusive use with R-Stage & Regular Head
Item No. 03-05-111(Carburetor kit) 03-02-035(Manifold kit)
Fit Monkey
Fit Gorilla Frame Nos Z50J-1300027∼
Fit Monkey BAJA
Frame Nos Z50J-1300017∼
Frame Nos Z50J-1700001∼
・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.
the manual.
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◎ 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. So, 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.
Caution
The following show the envisioned possibility of injuries to human bodies or property damages as a result of disregarding the following 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.)
・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.)
Warning
The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the 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.)
・Before riding, always check every section 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.)
・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 ∼
１ ２
６
１０
７
３
８
１１
１２
４
９
５
Factory preset mode of the carburetor
Main jet
Slow jet
Jet needle
Clip position
＃95
＃35
E2051G
4th from the top
Throttle valve
Air screw opening
74B
1-1/4
No.
1
＊ 2
＊ 3
＊ 4
5
＊ 6
＊ 7
＊ 8
＊ 9
10
11
Part Name
Carburetor assembly
Inlet pipe
Carburetor gaslet
Inlet pipe gaslet
Throttle cable COMP. 810
Lock nut, 6 mm
Socket cap screw, 6x20
Socket cap screw, 6x70
Socket cap screw, 6x25
Fuel cock
Main jet, #105
1
1
1
2
Qty
1
1
2
1
1
1
1
12 Slow jet, #42
＊ TOOL Hex wrench, 5mm
1
1
※marks indicate the contents of a manifold kit.
- 1 -
Installation Procedure
Please check the contents of this kit.
６．Place the carburetor gaskets between
carburetor and inlet pipe, and tighten them
(Preparation)
to the specified torque with two M6x25
CAUTION: Make sure that the engine and the muffler are cold enough!!
socket cap screws and two lock nuts.
Stabilize the vehicle!!
２．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.
the gasoline in the fuel tank. Close the fuel cock, pull out the fuel hose
from the carburetor, and demount the fuel tank.
detach the throttle valve from the carburetor. Demount the carburetor
Torque=10 N・m (1.0 kgf・m)
７．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
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carburetor.
９．Place the inlet pipe gaskets between
cylinder head and inlet pipe, and tighten them
to the specified torque with two M6x20
socket cap screws.
with all the air cleaner box and inlet pipe attached to it.
※ Be careful not to let any foreign material get into the intake port.
Torque=10 N・m (1.0 kgf・m)
※ 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.
４．Unfasten the throttle valve from the carburetor. Separate the throttle
valve from the throttle cable. And remove the top cover from the throttle
cable.
５．Unfasten the pan screws on the throttle
housing to disconnect the throttle cable.
Wipe off dirt and worn-out grease.
※ Be careful not to lose the throttle housing
or pan screws for reuse.
６．Fix the ground wire to the frame with the
air-cleaner mounting bolt.
７．Keep those detached parts in a bag or the like.
１０．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.
※Also check that the throttle has free play
even when a steering handle is turned
all the way to the right and left.
１１．If the fuel tank is removed, install and
tighten a new fuel cock to the specified
torque of 5 ∼ 6N･m(0.5 ∼ 0.6 kgf･m),
and reinstall the fuel tank and mount the
seat.
(Installation)
CAUTION: Be sure to tighten to the specified torque with a torque wrench.
１．Temporarily attach the throttle cable to the under throttle housing, and
connect the inner cable with the throttle pipe.
２．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)
３．Remove the float chamber from the PD22
carburetor, and replace the main and slow
jets with those of the Kit.
Main jet
Slow jet
(Pilot screw)
１２．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.)
１３．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.
４．Reinstall the float chamber in its original
position.
Float chamber
１４．Adjust the setting to meet the motorcycle in a safe place with utmost
care.
Notch
Throttle stop screw
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
valve spring and the throttle valve.
- 2 -
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:
・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 works well if the cleaner is detached.
・The motorcycle belches dense (or, black) exhaust gas.
・The plug smolders, getting blackened.
When the air-fuel mixture is too lean:
・The engine overheats somewhat.
・The engine starts working well If you use the choke,.
・The engine does not accelerate well. (No smooth acceleration)
・Revolutions change, generating weak power.
・The plug burns white.
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.
○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.
○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
