Big Carburetor Kit (KEIHIN PE24) Instruction Manual
Product number

03-05-0225 (Carburetor kit)
03-02-0001 (Manifold set)Ape 50(AC16-1000001 ～ 1499999)
Ape100(HC07-1000001 ～ )Ape100 Type D (HC13-1000001 ～ )Adaptation model XR 50 Motard (AD14-1000001 ～ )XR100 Motard (HD13-1000001 ～ )XR 100R(HE03-2100001 ～ )CRF100F(HE03-2400001 ～ )Requirement
Our Super-Head-equipped motorcycle

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.

CO☆ Please read carefully before use ☆

◎ 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 this Instruction Manual.
◎ We shall be held free from any kind of warranty whatsoever of products other than this product if the glitch takes place on theother 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’.
◎ This product is designed for exclusive use in the above-mentioned types of motorcycles and frame numbers only. Please take note that
this product cannot be mounted on other types of motorcycles.
◎ For the installation of this Kit onto a drum-brake motorcycle, a brake lever & wire set of 06-08-3001 are separately required.
◎ It is advisable to use this Kit together with our optional mudguard.
◎ This Kit is for exclusive use with motorcycles equipped with our Super Head and our PE24 Carburetor Kit.
Do NOT use this Kit on motorcycles equipped with a standard head.
◎ The engine will go wrong if it gets wet. So, refrain from riding your motorcycle in the rain. In addition, when washing your vehicle,
be careful not to let the water into the engine via an air filter.
◎ Depending on the natural phenomena like the weather, humidity, temperatures, altitudes and barometric pressure, and specifications of
the individual motorcycle and carburetor, the carburetors need re-setting. Be sure to rearrange the setting to match the engine andother conditions of your motorcycle.
For your information, the carburetor is shipped out in a state described on page 2.
◎ This Kit is designed for exclusive use in the closed racing. So, take note that it is prohibited to ride your motorcycle on a publicroad after the installation of this Kit.
◎ A standard muffler and carburetor interfere with each other on Ape100 with a frame # from HC07-1600001 onwards and on Ape type D witha frame # from HC13-1000001 onwards. This Kit is designed for use only on motorcycles equipped with a full-exhaust muffler.
◎ When a battery is to be used on Ape 100 with a frame # from HC07-1600001 onwards and on Ape type D with a frame # from HC13-1000001
onwards, a battery box and mud guard are required additionally. Moreover, the installation of a Fenderless Kit is needed for runningon public roads.
NOTE that a standard fender cannot be installed.
CautionPY

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

■ 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.)■ 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.)■ 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. (Or improper torque may cause parts to come off.)
Warning

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

■ When you notice something abnormal with your motorcycle while riding down a road, stop riding immediately and park your motorcyle ina safe place. (Otherwise, the abnormality could lead to accidents.)■ Before doing work, secure the motorcycle 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 parts correctly according to the procedures in the instruction manual or a service manual.
(Improper checking or maintenance could lead to accidents.)■ If you find damaged parts when checking and performing maintenance, do not use these parts any longer, and replace them with newones. (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. (It may cause a fire.)■ Plastic bags of product packaging, you can either be stored in a place that is out of reach of children, it should be discarded.
(When the children or wearing, there is a risk of suffocation.)◎ 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 inracing 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)2022.10.14

03-05-0225,03-02-0001

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Product content②③④⑤⑦①⑥03-02-0001

CO⑩⑪⑫09-02-0222⑧⑨⑱㉑⑬⑲⑭⑮㉓⑯⑳⑰㉒

Number123456789※ 10※ 11※ 1213※ 14※ 15※ 1617181920212223

Product contentConnecting tube
Air filter
Air filter stay
Flange bolt, 6x16
Flange U nut, 6mm
Clamp band (40-60mm)
Carburetor ASSY.(PE24)
Main jet, #120
Slow jet, #40
Carburetor insulator
Clamp band (30-45mm)
Socket cap screw, 6x15 (SUS)
L-joint, 10mm
Inlet pipe
CollarO-ringFuel tube, 200mm
Throttle COMP.
Grip rubber, right
Grip rubber, leftThrottle cable COMP. 710mm
Hex wrench, 3mmHex wrench, 5mm

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Quantity
Item Number
100-03-0415
100-03-0391
100-00-1513
100-00-0134 (4 pcs)
100-00-0091 (6 pcs)
100-00-0038
103-03-0074
100-03-0098
100-03-0170
100-03-0209
100-00-0050
400-00-0205 (4 pcs)
100-03-0207
100-00-1475
100-00-1460
100-03-0206
100-03-0203 (500mm)
1
109-02-0002
1109-02-0071
11※ marks indicate the contents of a manifold set.
∴ 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.

2022.10.14

03-05-0225,03-02-0001

/4Factory preset mode of the carburetor
Main jetSlow jetJet needle
Clip position
Throttle valve cutaway
Air screw opening

#108
#48
36S
3rd groove
#3.0
1-1/2

■ Mounting procedure※ Please refer to the Genuine Service Manual for detailed mounting methods and specified torques that are notspecifically described.

Removal of a genuine carburetor○ Unfasten two bolts, and pull the seat toremove it.
○ Unfasten a bolt on the right side cover.
And unfasten two bosses on the frame toremove the right side cover.
○ Remove three bosses on the left side
cover from the frame to unfastenthe left
side cover.
○ Detach the storage tank hose and the
carburetor air bent tube from the side ofan air cleaner case.
※ Remove the storage tank hose along withthe breather tube joint.

○ Detach a connecting tube from the carburetor,and remove the air cleaner case.
○ Apply an adhesive to the connecting tube,and align the holes of an air filter and abracket, and fit the connecting tube.
※ Removing the dirt and oil from the contact
surfaces and drying the adhesive on thecontact surfaces sufficiently, apply a thincoat of“Honda Bond A”or the equivalent,
and fix an air filter prior to the contact
surface drying.
※ Use the adhesive, referring to its
instructions.
※ Leave the air filter intact at least two hours
after fixing it so the adhesive dries out.

COInstallation of the carburetor○ Remove the float chamber from the PE24
carburetor, and replace the main and slow
jets with those included in the Kit, andreinstall back the float chamber into its
original location.
○ Fit a provided O-ring to the grooves on
the reverse side of the inlet pipe.
And install the inlet pipe with anattached O-ring onto the cylinder headwith a socket cap screw and tighten it tothe specified torque.
Note: Be sure that you protect specifiedtorque.
Socket cap screw

Torque：10N・m（1.0kgf・m）

Storage tank tube

O-ringAir bent tube

○ Loosen a screw on the connecting tube band.

○ Close the fuel cock, and open the draincock on the carburetor.
Drain the gasoline in the float chamber toa container.
○ Remove a fuel tube from the carburetor.
Detach the carburetor top and detach thethrottle valve from the carburetor.
Disconnect the throttle valve and throttle
cable, and pull out the top cover.

○ Attach a provided insulator onto theinlet pipe as assembled above with asocket cap screw and tighten it to thespecified torque.

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Note: Be sure that you protect specifiedtorque.
Socket cap screw

Torque：10N・m（1.0kgf・m）

Top cover○ Remove two case mounting bolts from theleft side and one from the right side,
all of which are fixing the stock aircleaner case.

Insulator

Socket cap screw

Insulator band, 30 - 45 mm

Fuel tube○ Unfasten the inlet-pipe-mounting bolt, andremove the inlet pipe.
※ Be careful not to let any foreign material
fall into the intake port.

○ Attach a (30-45mm) insulator band to thecarburetor insulator.
○ Attach a provided collar to the openingof the carburetor, referring to the figure.
※ The above work is not required in case aconnecting tube is not to be installed.

On thecarburetor side
Chamfer

Chamfer○ When a battery is to be used on Ape100
with a frame # from HC07-1600001 onwards
or with a frame # from HC13-1000001 onwards,
fit the battery, referring to the instructions for the battery box and therelevant Kit.
2022.10.14○ Unfasten a pan head screw on the throttle
housing from the motorcycle.

03-05-0225,03-02-0001

/4

■ Mounting procedure※ Please refer to the Genuine Service Manual for detailed mounting methods and specified torques that are notspecifically described.

○ Unfasten a screw on the throttle housingincluded in the Kit to disassemble thehousing.
○ Apply grease to the sliding surface ofthe handle throttle pipe and install thethrottle pipe.
○ Attach and tighten the throttle cableloosely for now to the lower housing, andconnect the cable ends to the throttle pipe.
※ Apply grease to the cable ends and tothe cable-rolling portion of the pipe.
The inner wire will protrude about 9 mm longer.

○ Fit the carburetor into the insulator andfasten the carburetor with a clamp band.

○ Tighten the throttle-cable locking nut.
※ NOTE that fastening the locking nut too
tight may break the housing.

COStandard
mounting location

Note: Be sure that you protect specified torque.
Throttle-cable locking nut

Torque：8N・m（0.8kgf・m）○ Adjust the free play on a throttle cableby the adjuster so there is approx. 5 mm
of free play at the throttle grip.

○ Install the upper housing and tighten ascrew.

About 5mm

Note: Be sure that you protect specifiedtorque.
Screw○ Fit a storage tank hose into a connecting
tube, and put a tube clip.
※ Tie an air vent tube in a bundle so thatit does not get in the way of your riding.
※ When installing onto XR100R or CRF100F,
install a vent tube with an L-joint
included in the Kit.
○ Attach a right and a left side cover,
and a seat. Open the fuel cock and checkfor oil leaks. (Do not leave the cock
open for a long time.)○ Pull the choke lever to start the engine.
Gradually release the choke lever andwarm up the engine till the revolution
becomes smooth, and finally let go of thelever so it returns to its original position.
In case the engine does not run idle, oridles away at high revolutions after thewarm-up, adjust the setting with a throttle
stop screw.
○ At the safe place and with great care,do the setting to match the specificationsof an individual motorcycle.

Torque：5N・m（0.5kgf・m）○ Remove the dirt and oil on the gripmounting surface of the steering handle
and the throttle pipe and inside theright- and left-hand rubber grips.
Apply a thin coat of Honda’s genuine
Honda Bond A or Cemedine F540 to thehandle and throttle pipe, and attach thegrip rubber to the handle and the gripmounting surface, while rotating the grips,
before the bonded surfaces get dry.
○ Remove the top cover of the carburetor
included in the kit, and pull out a spring
and throttle valve. And then, pass theinner cable of the throttle cables throughthe top cover of the carburetor, and thenpass the spring. And compressing thespring, attach it to the throttle valve.
Aligning a notch on the throttle valve withthe throttle stop screw, attach thethrottle valve to the carburetor.

○ Snap the throttle a few times to make surethat the throttle moves smoothly without
sticking and that the throttle valve is fully
open.And check that the throttle has freeplay even when a steering handle is turned
all the way to the right or to the left.
○ Put in a fuel tube and fasten it with atube clip.

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Installation of the air filter andconnecting tube

○ Fit a (40-60mm) clamp band into the connecting
tube, which please install onto the carburetor
and tighten it with the clamp band.

○ Fit the air-filter bracket onto the mounting
hole on the air cleaner case on the rightside of the frame, with a 6x16 flange bolt
and flange U nut.
Note: Be sure that you protect specified torque.
Flange bolt

Torque：12N・m（1.2kgf・m）

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03-05-0225,03-02-0001～ How to perform
maintenance ～/4

It is easy to perform the maintenance of ahigh flow filter included in the Kit.
And when the element is stained, performthe maintenance as follows:(Never use chemical products like a stan
dard filter cleaner or filter oil. Otherwise,
the element will be likely to deteriorate.)○ Detach it from the motorcycle and remove
dusts gathered on the element surface.
○ Prepare cleaning liquid out of mild
detergent available on the market,
diluting it with water, and soak thefilter in the cleaning liquid to clean
the element.
(Never scrub the element with a hardbrush or rub it hard. Otherwise, theelement will be damaged.)○ Pour the running tap water into theinside of the element to thoroughly rinse
the cleaning liquid out of the element.
○ After rinsing off the cleaning liquid,
dry the element. Wipe off the moistureon the element with a waste cloth as if
to press the cloth against the element,
and place it in the airy shade to let it
dry naturally.
In case you use compressed air, let theair into the inside of the element withlow pressure to blow off the moisture.

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)

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・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