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Key instructions and disclaimers for product use and installation.
Envisioned possibility of injuries to human bodies or property damages.
Envisioned possibility of human death or serious injuries to human bodies.
Step-by-step guide to detach the original carburetor from the motorcycle.
Steps to prepare the motorcycle body before installing the new carburetor.
Detailed steps for mounting the new carburetor onto the intake manifold.
Adjusting the throttle grip free play and ensuring smooth throttle operation.
Instructions for cleaning and drying the air filter element.
Adjusting air-fuel mixture density via E-ring groove position.
Adjusting air-fuel mixture density by changing the main jet size.
Selecting the correct pilot jet based on air screw adjustment.
Adjusting air mass flow at slow speed for optimal idling.
Understanding how environmental factors influence carburetor settings.
This document provides comprehensive instructions for the installation, adjustment, and maintenance of the KEIHIN PD22 Carburetor Kit, designed for the TT-R90 (5HN) motorcycle. It emphasizes safety, proper installation techniques, and carburetor tuning to ensure optimal engine performance.
The KEIHIN PD22 Carburetor Kit is a performance-enhancing component designed to replace the genuine carburetor on the TT-R90 (5HN) motorcycle. Its primary function is to precisely mix air and fuel, delivering the optimal air-fuel ratio to the engine's combustion chamber. This precise control over the air-fuel mixture is crucial for efficient combustion, leading to improved engine power, responsiveness, and overall performance. The kit includes the PD22 carburetor itself, an intake manifold, a high-flow air filter, a throttle cable, various gaskets, and mounting hardware. The high-flow air filter is designed to allow more air into the engine, complementing the carburetor's ability to deliver a richer mixture when needed for performance. The kit also provides specific settings for the main jet, slow jet, jet needle, throttle valve cut-away, and air screw opening, which are factory preset to offer a balanced starting point for tuning.
The carburetor kit is designed for exclusive use with the specified motorcycle model, ensuring compatibility and optimal integration. Users are advised to carefully follow the installation procedures outlined in the manual. Before installation, it's essential to verify all kit contents. The installation process involves removing the genuine carburetor and related components, preparing the motorcycle frame for the new carburetor and air filter by bending or cutting interfering stays, and then mounting the new components. The throttle cable needs to be routed correctly, and the throttle grip adjusted for approximately 5 mm of free play. This adjustment is critical for smooth throttle operation and to prevent the throttle valve from sticking or remaining partially open. Once installed, the fuel tank is reconnected, and the fuel cock is opened to check for leaks.
A key aspect of using this kit is carburetor tuning, which is necessary to match the engine's conditions, weather, temperature, altitude, and barometric pressure. The manual details how to adjust the jet needle, main jet, pilot jet, and air screw to achieve the ideal air-fuel mixture. For instance, adjusting the E-ring position on the jet needle affects the mixture at 1/4 to 3/4 throttle, while changing the main jet number impacts the mixture at 3/4 to full throttle. The pilot jet and air screw are crucial for tuning the engine's performance at idle and slow speeds. The manual provides clear indicators of whether the air-fuel mixture is too dense or too lean, such as engine overheating, poor acceleration, black exhaust smoke, or a dull thudding sound during explosion. Users are guided to adjust these settings until the engine runs smoothly, accelerates well, and idles steadily.
Maintaining the KEIHIN PD22 Carburetor Kit primarily involves proper cleaning of the high-flow air filter and periodic carburetor adjustments. The supplied air filter uses a sponge element, making it easy to wash. The cleaning process involves detaching the air filter, removing dust and dirt from its surface, and then soaking it in a cleaning liquid made from mild detergent and water. It's crucial not to scrub the element with a hard brush or rub it harshly, as this can damage it. After cleaning, the element should be thoroughly rinsed with running tap water to remove all cleaning liquid and then dried naturally in an airy shade. The manual explicitly warns against using chemical filter cleaners or filter oil sold on the market, as these can deteriorate the element.
Beyond air filter maintenance, the carburetor itself requires attention. The manual advises checking for oil leakage after connecting the fuel tank and opening the fuel cock. Regular checks for loose screws and nuts are also recommended, with instructions to tighten them to the specified torque to prevent parts from falling off and causing accidents. The manual also highlights the importance of inspecting parts for damage during maintenance and replacing any damaged components immediately to prevent further issues. Environmental factors such as barometric pressure, temperature, and humidity can affect the air density and thus the air-fuel mixture. Therefore, periodic carburetor re-setting may be necessary to maintain optimal performance under varying conditions. For example, at high altitudes or in cold weather, adjustments to the air-fuel mixture may be required to compensate for changes in air density. The manual emphasizes the importance of performing all work on a level ground with the engine and muffler cool, using appropriate tools, and protecting hands from sharp edges.
General| Type | Carburetor |
|---|---|
| Model | KEIHIN PD22 |
| Bore Size | 22mm |
| Manufacturer | Takegawa |
| Application | Motorcycles |
