Instruction Manual for KEIHIN PD22 Carburetor Kit
Contents
1. yy Instruction Manual for KEIHIN PD22 Carburetor Kit R Stage D Regular Head Item NoQUU UU UUUU Applicable Models Frame Nos Monkey Z50J 130001 7 Gorilla Z50J 1300027 Monkey BAJA Z50J 1700001 O Thank you for purchasing one of our TAKEGAWA s products Please strictly follow the following instructions in installing and using the products O 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 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 products 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 You are kindly requested not to contact us about the combination of our products with other manufacturers A stock air cleaner cannot be equipped together with this kit The engine will go wrong if it gets wet So please refrain from running in the rain Besides before washing your vehicle cover the carburetor with a plastic sheet or the like to prevent water2. Mainjet A nstallation Procedures O Route the kit s throttle cable to the O0 O U If you have removed the fuel tank replace the stock fuel cock with the one from the kit the specified torque 50 6 N m 0 5 0 6 kgf m and attach the fuel tank and the seat carburetor without tightening it up Fix the carburetor top to the throttle cable and then the inner cable to the throttle valve with the throttle valve spring compressed O O Aligning a notch on the throttle valve with a throttle stop screw install it to the carburetor O0 O O Make adjustments of the direction of the fuel cock and the length of the fuel tube then insert them into the fuel cock and the carburetor and fix the tube clip Open the fuel cock and check for oil leak Do not leave the cock open for a long time Notch Throttle stop screw 0 0 Place an 7 inlet pipe gasket between the cylinder head and the inlet pipe and fix it by tightening two socket cap screws M6x20 to the specified torque Specified torque 10 N m 1 0 kgflim O Attach the air filter which please fasten with a band O0 O O Dispose of the blow by gas from the crank case by yourself In some cases racing and regulations stipulate the disposal of the blow by gas of the frame and other parts the carburetor and the frame may interfere with each other If so rasp the interferring part Pull the choke lever to
3. 1 lt i 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 take them in the quantity packed PD22 Slow J et 00 03 0137 00 03 0138 00 03 0139 00 03 0140 PD22 Main J et 00 03 0032 00 03 0033 00 03 0034 00 03 0020 100 00 03 0147 wy Apr 25 09 F Check the kit contents Installation Preparation Caution Make sure that the engine and muffler are cool and that the motorcycle is secure O Oin the case of the Gorilla and Monkey BAJA remove a seat drain gasoline in the fuel tank shut the fuel cock pull out the fuel hose on the carburetor side and then remove the fuel tank O O Confirming that the fuel cock is shut off open a drain cock on the carburetor to drain gasoline from the float chamber onto an oil container O O Unfasten the inlet pipe tightening bolt and air cleaner mounting bolts Remove a throttle valve from the carburetor Then remove the carburetor with the air cleaner box and the inlet pipe and all x Be careful not to let any for eign substance into the intake port O O Remove the throttle valve from the carburetor and separate the throttle valve from the throttle cable Then pull out the top cover from the thr
4. 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 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 aff
5. start the engine and check each section for intake leak Gradually pushing the lever back warm up the engine till the revolution becomes smooth And then push the lever back into the original location If the engine does not run idle or it runs idle at high revolution after warming up adjust the UU TR O0 O O Adjust the free play atthe throttle grip to be about 5 mm by turning the adjuster of the throttle cable Snap the throttle a few times to see that the throttle moves smoothly without sticking and that the revolution with the throttle throttle valve is fully open stop screw Check that there is a free play 0 0 O Work in a safe place with eet Sen a care and arrange the setting turn the steering handle all the oomaich each Vehicle way to the right and left SPECIAL PARTS AZIYA 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 Apr 25 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 y
6. d lead to an accident O Always start the engine in a well ventilated place and do not turn the engine on in an airtight place Otherwise you will suffer from carbon monoxide poisoning 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 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 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 Please retain this Instruction Manual for future reference A Sie Apr 25 09 f N Kit Contents Factory preset mode of the carburetor Main jet 95 Slow jet 35 J et needle E2051G Clip position 4th from top Throttle valve 74B Air screw opening O tum 1 4 No 7 Part Name OW Repair Part Rem No Oty T73 GEFTOL a init pipe gasket O a o 5 moie cable co eo a oaa 1 6 Locking nut 6 mm 2 00 00 0121 20 7 Socket cap screw M6 x20 1 fooroo coas o 8 Socket cap screw M6 x 70_ 7a fooanans E o socket cap screw 6x25 2 oo a0 fFuet cock 008 001 03 01 1064 maine 05 CYC f OT E powere 1 ooo i fewmnsm
7. ect 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
8. from getting into the carburetor This kit s carburetor is factory pre set as per page 2 Setting should be adjusted according to the parts to be used Re set the carburetor to meet your engine Be sure to do the work correctly referring to the HONDA genuine parts service manual for the above mentioned applicable model The following show the envisioned possibility of injuries to human bodies and property damage as a result of disregarding the following cautions Always use a torque wrench to screw bolts and taps tight and securely to the specified torque Improper torque could cause these parts to get damaged or fall off O Work only when the engine and muffler are cool at below 35 degrees Celsius 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 VN Warning 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 Parts breakage and others may cause falling and accidents Before riding be sure to check every section for slack in parts like screws and oil leak When you notice something abnormal with your motorcycle while riding immediately stop riding and park your motorcyle in a safe place Otherwise the abnormality coul
9. ottle cable O O Unfasten the pan screws on the throttle housing and disconnect the throttle cable Wipe off dirt dust and old grease X Be careful not to lose the throttle housing and pan screws which will be reused LI O O Hold the earth cable to the frame with an air cleaner mounting bolt 0 O Keep the removed pais in a bag or something else Installation A Caution Be sure to tighten to the specified torque with a torque wrench O0 O Temporarily attach the throttle cable to the under throttle housing and connect the inner cable with the throttle pipe O O Apply grease to the sliding surface on the throttle and install the throttle housing Tighten the pan screws Specified torque 8 Nim 0 8 kgf Jm O O Detach a float chamber in the PD22 carburetor and replace the main and slow jets with those in the kit ae Float chamber 7 N w Qe ot MLE O O Reinstall the float chamber where it was originally O Detach the top cover from the PD22 type carburetor and then the throttle valve spring and the throttle valve 0 O Place a carburetor gasket between the carburetor and the inlet pipe and fix it by tightening two socket cap screws 6x25 and two locking nuts to the specified torque Specified torque 10 N m 1 0 kgf Im
10. ou 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 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
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