Big Carburetor Kit (PE28) Instruction manual(For exclusive use in the Super Head 4VALVE+R-equipped motorcycle)
Product number

03-05-0032 (Carburetor Kit)
03-02-2566 (Manifold Set)

Adaptation model

Monkey / Gorilla (Z50J-2000001 ～ 2699999)(AB27-1000001 ～ 1809999)

Thank you very much for purchasing our products.
Thank you so you will comply with the following matters at the time of use.Before installation, please check your always kit contents.
If there is a point of notice event, Please contact us the dealer of purchase.
◎ If the description, such as photos or Illustration different with this part.

☆ Please read carefully before use ☆

CO◎ We do not take any responsibility for any accident or damage whatsoever arising from the use of the kit not in conformity with theinstructions 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 otherproducts than this one after the installation and use of this product.
◎ This carburetor kit is for exclusive use in a motorcycle equipped with a TAKEGAWA-made Super Head 4VALVE + R Bore Up Kit and Bore
Stroke Up Kit. This kit is compatible only with a stock engine and Super Head 4VALVE + R.
◎ Do the installation work correctly referring to the relative genuine service manual for the above-mentioned compatible models.
◎ Please note that this kit is designed for exclusive use in the above-mentioned compatible 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, thecarburetor is shipped out in a state described on page 2.
◎ In installing this kit, a stock throttle housing is not used. Therefore, a brake lever and others need to be prepared by the user.
◎ This kit is designed for exclusive use in the closed racing. So, do not drive your motorcycle on a public road after theinstallation of this kit. Drive your motorcycle at a legal speed, abiding by the laws.
CautionPY

When the handling of ignoring this display, property damage and human shows the assumption of what injury.

■ Make sure the engine and muffler are cool before starting the installation. (Otherwise, you will burn yourself.)■ 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, 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 section for slack in parts like screws. If you find slack ones, screw them securely up to thespecified torque. (Otherwise, improper tightening may cause parts to come off.)■ Always use new gaskets, and seals. And check those parts to be reused for wear and damage. If you find worn or damaged parts, replacethem with new ones.
Warning

When the handling of ignoring this display people died, shows the contents of the serious injury possibility isassumed.

■ 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.)■ 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 and performing maintenance of your motorcycle, do not use these parts any longer, and replacethem with new ones. (The continued use of these damaged parts could lead to accidents.)■ 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 note. Performance up, the design change, the product and the price in the cost up, etc. are subject to change without notice.
◎ Please be informed that we shall be held harmless against any claim against us whatsoever arising out of use of the products in
racing and the like.
◎ Keep this manual stored until this product is discarded.
CONTACT Address : 3-5-16 Nishikiorihigashi Tondabayashi Osaka JAPANTEL: +81-721-25-1357 FAX:+81-721-24-5059 e-mail:english@takegawa.co.jp URL http://www.takegawa.co.jp
Please contact with your name and country name provided. (Only English please)2022.10.24

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Product content

09-02-0221①

Optional part⑨⑩⑧⑪

Throttle cable,
710mm
09-02-0071⑫03-02-2566

CO②

③

④

NumberProduct content
1
Carburetor assembly
2
Inlet pipe
3
Insulator
4
Insulator band
5
Inlet pipe gasket
6
Socket cap screw, 6x157Socket cap screw, 6x25
8Air filter
9Throttle COMP.
10 Throttle Cable, 810mm
Pair of throttle grips,
11for right- & left-hand
12 Fuel hose, 200mm
13 Main jet, #110
14 Main jet, #115
15 Slow jet, #35
16 Hex wrench, 5mm⑤⑥⑦Quantity
Item Number
103-03-027
100-00-1493
100-03-0211
100-00-0050
100-03-0007 (2 pcs)
200-00-0718 (5 pcs)
200-00-0722 (5 pcs)
103-01-1064
1109-02-0081⑬ ⑭ ⑮PY

109-02-0002

1111
100-03-0203 (500mm)
00-03-009400-03-0096
00-03-0137⑯Factory preset mode of the carburetor

Main jetSlow jetJet needle
Clip position
Throttle valve cut-away
Air screw opening

#128
#52
F1343H24NAAC
2nd groove from top#6.0
1 ± 1/4 turns※ Please order in the repair parts are always repair part number.
If it is not the part number order, you may not be able to order.Please be forewarned.
It should be noted, In the case of parts that can not be separately shipment, please order a set part number.

PE28 Slow jet
Item No.
00-03-0137
00-03-0138
00-03-0139
00-03-0140
00-03-0313
00-03-0142
00-03-0143
00-03-0144
00-03-0145
00-03-0148
00-03-0149
00-03-0150

Product
Name
#35
#38
#40
#42
#45
#48
#50
#52
#55
#62
#65
#70

PE28 Main Jet

Item No.
00-03-0130
00-03-0131
00-03-0132
00-03-0133
00-03-0134
00-03-0135
00-03-0136
00-03-0090
00-03-0091
00-03-0092
00-03-0093
00-03-0094

Product
Name
# 82
# 85
# 88
# 90
# 92
# 95
# 98
#100
#102
#105
#108
#110

Item No.

00-03-0095
00-03-0096
00-03-0097
00-03-0098
00-03-0099
00-03-0100
00-03-0101
00-03-0102
00-03-0103
00-03-0104
00-03-0105
00-03-0106

Product
Name
#112
#115
#118
#120
#122
#125
#128
#130
#132
#135
#138
#140

Item No.

00-03-0107
00-03-0108
00-03-0109
00-03-0110
00-03-0111
00-03-0112
00-03-0113
00-03-0114
00-03-0115
00-03-0116
00-03-0117
00-03-0118

Product
Name
#142
#145
#148
#150
#152
#155
#158
#160
#162
#165
#168
#170

Item No.
00-03-0119
00-03-0120
00-03-0121
00-03-0122
00-03-0202
00-03-0123
00-03-0124
00-03-0125
00-03-0126
00-03-0127
00-03-0128
00-03-0129

ProductName
#172
#175
#178
#180
#182
#185
#188
#190
#192
#195
#198
#200

☆ 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.
☆ A standard air cleaner cannot be installed to this carburetor kit. Therefore, the engine will go wrong if water gets into the engine
and please refrain from driving in the rain. Besides, before washing your vehicle, cover the carburetor with a plastic sheet or thelike to prevent water from getting into the carburetor.
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■ Mounting procedure※ Please refer to the Genuine Service Manual for detailed mounting methods and specified torques that are notspecifically described.

● Please check the kit contents.

（Preparation forInstallation）
Note:Check that the engine andmuffler are cool and thatthe motorcycle is secureon level ground.

○ Referring to the service manual,demount the engine from theframe.
And with reference to theinstallation procedures for theSuper Head 4VALVE + R, install theSuper Head 4VALVE + R to theengine, and mount the engine
onto the frame.

○ Making sure that the fuelNote:Do follow the instructions
cock is closed, open a drainin the service manual.
plug on the carburetor, andNote:Be sure to tighten to thedrain the gasoline from thespecified torquefloat chamber to a tray.
○ Unfasten the inlet-pipe（Installation）
tightening bolt and air○ Pass the supplied throttlecleaner-mounting bolts.
cable through the frame.
Remove a throttle valve from○ Pass the supplied throttle
a carburetor. Then remove thecable through the lower throttle
carburetor with the air cleaner
housing, and connect the innerbox, the inlet pipe and all.
cable to the throttle pipe.
And attach the throttle housing※ Be careful not to let any
to the handle with two screws.
foreign materials fall into
※ Apply grease to the rubbing
the intake port.
surface of the throttle pipe,
the cable end, and to theportion on the pipe to take up
the cable.

CO

Note: Be sure that you protect
specified torque.
Screw○ Fasten the insulator to theinlet pipe with two socket cap
screws.
Note: Be sure that you protect
specified torque.
Socket cap screw

Torque：10N・m（1.0kgf・m）○ Remove a float chamber, andthen a main jet.
Attach a supplied main jet #110
and slow jet #35, and then afloat chamber.
○ Remove a top cover of the
supplied carburetor, and pullout the spring and the throttle
valve.
Pass the inner cable of thethrottle cable through thecarburetor top cover and thenthrough the spring.
And compressing the spring, fix
the top cover to the throttle
valve.
Fix the throttle valve to thecarburetor by aligning a notchon the throttle valve with thethrottle stop screw.

Torque：5N・m（0.5kgf・m）

Note: Be sure that you protect
specified torque.
Socket set screw

Torque：5N・m（0.5kgf・m）

ABBA○ Fit the carburetor into theinsulator, and fasten thecarburetor with a clamp band.

○ Place an inlet pipe gasket
between the cylinder head andthe inlet pipe, and fix it bytightening 6x25 socket cap
screws to the specified torque.

○ Fix an ground wire to theframe with an air-cleanermounting bolt.

Note: Be sure that you protect
specified torque.
Socket cap screw

Torque：10N・m（1.0kgf・m）

Inlet pipe

○ Attach an air filter, which
please fix by tightening a band.

Socket cap screw,6x25

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Less free playMore free play
Adjuster
About 5mm

○ Snap the throttle a few times
to make sure that the throttle
moves smoothly without sticking
and that the throttle valve
is fully open.
○ Insert a fuel tube and fasten
it with a tube clip.
Open the fuel cock and chockfor gas leaks. (Do not leave
the cock open for long time.)○ Dispose of the blow-by gas
from the crankcase by yourself.
(Some racing and regulations
specify the blow-by gasdisposal.)○ In sending back the blow-by
gas to the carburetor, connect
the blow-by hose with theunion 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 finallypush the lever back to its
original location.
In case the engine does not
run idle after the warm-upof the engine, or the engine
idling speed is high, adjust
the setting by turning thethrottle stop screw.
○ Jetting and other set up withyour engine specification,please do this set up at safe
and closed area such as
racetrack.

PY○ Attach socket set screws,
included in the Cylinder HeadKit, to two taps marked B on
the cylinder head surface toattach the inlet pipe to, andtighten the screws to thespecified torque.

○ Remove the throttle valve
from the carburetor, andseparate the throttle valve
from the throttle cable.
Then pull out the top coverfrom the throttle cable.
○ Unfasten a pan screw on thethrottle housing to remove
the throttle housing.

○ Adjust the free play at thethrottle grip to be about 5mmby turning the adjuster of
the throttle cable.

/3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:

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 works well if the cleaner is detached.
・The motorcycle belches dense (or, black) exhaust gas.
・The plug smolders, getting blackened.

・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.

CO※ 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.

3rd groove
2nd groove
4th groove

1st groove

5th groove○ Main jet (The throttle position at 3/4 - 4/4)

PY

・The air-fuel mixture ratio at this throttle position can be adjusted by changing the number of the main jet. The larger themain 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.

○ Slow jet / 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 slow jet / pilot jet with a small number.
・If you have tighten the air screw (clockwise) to the full, use a slow jet / 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 theidling to running at slow speed.
・When the engine revolves up unevenly, the slow jet / pilot jet number is too small. (At idle)
・When the motorcycle belches black exhaust gas and produces heavy exhaust sound, the slow jet / pilot jet number is too big. (At idle)
・After replacing the slow jet / 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 lessamounts.
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.

CONTACT Address : 3-5-16 Nishikiorihigashi Tondabayashi Osaka JAPANTEL: +81-721-25-1357 FAX:+81-721-24-5059 e-mail:english@takegawa.co.jp URL http://www.takegawa.co.jp
Please contact with your name and country name provided. (Only English please)2022.2.2