Instruction Manual for TAKEGAWA
Contents
1. yy Instruction Manual for TAKEGAWA made CARBURETOR SET to Install Keihin PE28 Carburetor Kit For exclusive use in Super Head R equipped motorcyles Item No f 0 0 0 0O O 0 O Carburetor set goo 0 0 O0 0 0 0 O Manifold kit Fitting models and the frame Nos Monkey Z50J 2000001 AB27 1000001 O 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 Read all instructions first 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 This carburetor kit is for exclusive use in a motorcycle equipped with TAKEGAWA made Super Head R Bore Up Kit and Bore Stroke Up Kit and is compatible only with a stock engine and Super Head R Do the installation work correctly referring to the relative Honda s genuine service manual fo2. 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 Always use new gaskets and packings And check those parts to be reused for wear and damage If you find worn or damaged parts replace them with new ones The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the Warning following warning 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 When you notice something abnormal with your motorcycle while riding immediately stop riding and park your motorcyle in a safe place to check what has gone wrong Otherwise the abnormality 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 O 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 O If y
3. pan screws on the throttle housing to remove the throttle housing Put an inlet pipe gasket between the cylinder head and the inlet pipe and tighten it with 6x20 and 6x45 socket cap screws to the specified torque Torque 10 N jm 1 0kgf Jm Note Be sure to follow the specified torque O Fix an earth wire to the frame with an air cleaner mounting bolt Fasten the insulator to the inlet pipe with two socket cap screws Torque 10 N jm 1 0kgf m Ne N Procedures O Remove a float chamber and then a O Adjust the free play at the throttle grip to be about 5 mm by turning the adjuster of the throttle cable See the figure below main jet Attach a supplied main jet 110 and slow jet 35 and then a float chamber Detach a top cover of the supplied carburetor and pull out the spring and the throttle valve Pass the inner cable of the throttle cable Less through the carburetor top cover and tree play then through the spring And compressing the spring fix the top cover to the throttle valve Fix More free play the throttle valve to the carburetor by aligning a notch on the throttle valve with the throttle stop screw Adjuster va ooo 5mm e bine sa 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 steerin
4. 00 03 0139 40 00 03 0140 42 00 03 0141 45 00 03 0148 62 00 03 0149 65 00 03 0132 88 00 03 0133 90 00 03 0134 92 00 03 0095 00 03 0096 115 00 03 0097 118 112 00 03 0101 128 00 03 0102 130 00 03 0103 132 00 03 0111 152 00 03 0112 155 00 03 0113 158 P Option Throttle cable 710mm HOU UU UU0U 128 52 F1343H24NAAC 2nd groove from top 6 0 1 1 4 tums 00 03 0117 168 00 03 0127 195 yx Setting of a carburetor must be adjusted depending on the natural phenomena like the weather temperatures and barometic pressure and machine and carburetor themselves Arrange the setting to match the engine and other conditions x A stock air cleaner cannot be equipped together with this kit The engine will go wrong if the engine gets wet So please refrain from running in the rain N Besides before washing your vehicle cover the carburetor with a plastic sheet or the like to prevent water from getting into the carburetor P _2 Apr 18 07 Installation Check the kit contents O Referring to the service manual Preparation for installation demount the engine from the frame A And with reference to the Note Make sure that the en installation procedures for the gine and muffler are cool Super Head R install the Super and that the motorcyle is Head R to the engine and then securely supported mount the eng
5. e 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
6. g handle is turned all the way to the right or to the left O Insert a fuel tube and fasten it with a tube clip Open the fuel cock and ckeck for oil leaks Do not leave the cock open for many hours O Dispose of the blow by gas from the crankcase by yourself Some races and regulations specify the blow by gas disposal O In sending back the blow by gas to the carburetor connect the blow by hose with the union on the air filter 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 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 Adjust the setting with utmost care in a safe place to meet the Snap the throttle a few times to O Fit the carburetor into the insulator and fasten the carburetor with a clamp band O Attach an air filter which please fix by tightening a band specification of each motorcycle SPECIAL PARTS Co Ltd 3 5 16 Nishikiorihigashi Tondabayashi Osaka Japan TEL 81 721 25 1357 FAX 81 721 24 5059 URL http Awww takegawa co jp A Apr 18 07 f How to Set the Carburetor O W
7. hen 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 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 groove
8. ine onto the frame Note Be sure to follow the service manual instructions and the specified torque 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 gasoline container O Unfasten the inlet pipe tightening Installation bolt and air cleaner mounting bolts Remove a throttle valve from a carburetor Then remove the carburetor with the air cleaner box the inlet pipe and all x Be careful not to let any foreign materials fall into the intake dials O Pass the supplied throttle cable through the frame O Fit the supplied throttle cable into the lower throttle housing and connect the inner cable to the throttle pipe And attach the throttle housing to the handle with two screws Xx Apply grease to the rubbing surface of the throttle pipe the cable end and to the portion on the pipe to take up the cable Torque 5 N m 0 5 kgf m Note Be sure to follow the specified torque Attach socket set screws included in the Cylinder Head Kit to two taps marked A on the cylinder head surface to attach the inlet pipe to and tighten the screws to the specified torque Torque 5 Ni m 0 5 kgf m A Note Be sure to follow the specified torque O Remove the throttle valve from the carburetor Separate the throttle valve and the throttle cable Remove the top cover from the throttle cable Unfasten
9. ou 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 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 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 VE This manual should be retained for future reference J aT Apr 18 07 N Kit Contents 0 UUU UL Main jet Clip position No PN y Pine Oy a rsu band O f a oo TS neppe 1 o a 6 esne 2 ooo 107 ACEC E ECESE 3 01 1064 i o fme coe ft eee C Mna a oo ST powes ooo S C fewn sm a e N take them in the quantity packed PE28 Slow jet PE28 Main Jet Factory preset mode of the carburetor Throtte valve cutaway Air screw opening x Please note that in ordering repair parts be sure to quote the Repair Part Item No Otherwise we may not be able to accept your orders There are some parts however for which we are not in a position to accept your order in just the quantity to be used In this case please
10. r the above mentioned fitting models Please note that this kit is designed for exclusive use in the above mentioned fitting models and frame numbers only and that it cannot be mounted on other models You are kindly requested not to contact us about the combination of our products with other manufacturers Setting of a carburetor must be adjusted depending on the natural phenomena like the weather temperatures and barometic pressure and machine and carburetor 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 A stock throttle housing is not to be used Therefore a brake lever etc need to be prepared by a user This kit is designed for exclusive use in the closed racing So take note that it is prohibited to drive your motorcycle on a public road after the installation of this kit Drive your motorcycle at a legal speed abiding by the laws The following show the envisioned possibility of injuries 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
11. s 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 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 mixtur
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