KEIHIN PD22 Carburetor Kit Instruction Manual

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Item No. ：０３―０５―０００５
Fit：TT-R90 (5HN)

・We are flattered that you have purchased one of our products. Please strictly follow the following instructions in installing and using the products.
・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 dealer.
◎ Please note that, in some cases, the illustrations and photos may vary from the actual hardware.

Please do read the following before 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 instructionsin the manual.
◎ We shall be held free from any responsibility or compensation whatsoever for any glitch in the parts other than ours if the glitch takes place after theinstallation and use of thse products.
◎ If you make modifications to the products, we shall be held free from any guarantee of the products.
◎ You are kindly requested not to contact us about the combination of our products with other manufacturers'.
◎ This Kit is designed for exclusive use in the above-mentioned suitable models and that it cannot be mounted on any other models.
◎ When ordering repair parts, please quote Item Nos or reference Nos in the figures in this Manual. Should you have any questions about the repair
parts, please contact your local motorcycle dealer.

PY◎ The air filter included in the Kit is designed to come with a cover to be more weather resistant. However, this does not guarantee the safety ofwashing with water or running in deep puddles.
When you are washing your motorcycle with a large amount of water, be careful not to let the water into the inside of the engine from the air filter.
◎ Depending on the natural phenomena like the weather, 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 and other conditions.
Factory preset mode of the carburetor is as per the description on the next page.
The following show the envisioned possibility of injuries to human bodies or property damages as a result of disregarding theCaution following cautions.

・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 the specified
torque. (Or improper torque may cause parts to come off.)
The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding theWarning following cautions.

・When you notice something abnormal with your motorcycle while riding down a road, stop riding immediately and park your motorcyle in a safeplace. (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 new ones.
(The continued use of these damaged parts could lead to accidents.)・Keep plastic bags for packing the products out of children's reach, or discard them.
(If children get them on, there will be a danger of their suffocating.)
・As gasoline is highly flammable, never place it close to fire. Make sure that nothing flammable is near the gasoline. Since vaporized accumulationof gasoline is at high risk of explosion, work in a well-ventilated place. (It may cause a fire.)◎ Please be informed that, mainly because of improvement in performance, design changes, and cost increase, the product specifications andprices are subject to change without prior notice.
◎ This manual should be retained for future reference.
‑1‑2021.2.10

〜 Kit Contents 〜
３２
７

１CONo.
1234
5
67
8
91011Part Name
Intake manifold (E-1)
Carburetor (PD22)
High flow filter
Throttle cable
Carburetor gasket
Intake manifold gasket
Socket cap screw, 6x65
Lock nut, 6 mm
Socket cap screw, 6x25
Socket cap screw, 6x20
Fuel hose

Qty
11
1
1
1
1
12
2
1
1１０

８

９４

６１１

Repair Part Item No.

in packs of03-03-0002
03-01-1138

1100-00-1456

100-00-0729
00-00-0533
00-00-0722
00-00-0721
00-03-0203

５510551

Factory preset mode of the carburetor
Main jetSlow jetJet needle
Clip position
Throttle valve cut-way
Air screw opening

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#95
#38
E2051G
4th from the top
74B
1-1/4 turns backward※ Please order repair parts with the Repair Part Item No. Without the repair part item No.,
we may not be able to provide the correct parts. Some parts are only available as a set. Please order them with the set number.

〜 Installation Procedures 〜〜 Removal of genuine
carburetor 〜１．Make sure your bike is secure on amaintenance stand on level and safe ground.
２．Remove both left and right side covers.
３．Close the fuel cock, open the drain cock on
the carburetor, and drain the gasoline fromthe float chamber to a tray.
Then, disconnect the fuel hose from the body.
４．Demount a seat, and remove the fuel tankfrom the motorcycle.
５．Loosen the clamp which is joining the aircleaner box and carburetor together.
And unfasten a screw holding the air cleaner
box, and remove the air cleaner box from thebody.
６．Detach a starter plunger lever (or, a chokelever) from the motorcycle.
７．Detach a carburetor top and two heater leadwires from the carburetor.
８．Remove the carburetor and intake manifold

Preparation for installing hardware to the body

１．First, write down how the genuine throttle cableis routed.
And then unfasten a screw on the throttle grip
cap, and remove the genuine throttle cable fromthe body.
２．Connect the provided throttle cable to thethrottle grip cap, and route it in the same way
as the one just written down.
３．As some of the stays fixed to the frameinterfere with the supplied carburetor and aircleaner, bend or cut off the interfering stays.
①：Either fold back the genuine air cleaner box
stay at an angle of 90 degrees or cut it off at
the base.
②：Either bend the lead guide of a thick wire in
the middle of the frame along the frame, orcut it.
③：Fold back the thermostat stay upward at anangle of 45 degrees.

４．Secure the heater lead wire so it does not
short-circuit with the frame.

③

from the body.
９．Cover the intake port on the cylinder headwith a waste cloth to prevent the dust andforeign objects from getting into it.

①②‑2‑2021.2.10

〜 Installation of Carburetor 〜 Adjustment and installation of
１．Take off the waste cloth placed on the intake
port. And place the intake manifold gaskets
between the supplied intake manifold andcylinder head. And fasten the intake manifold
onto the cylinder head with 6x65 and 6x20
socket cap screws.

exterior

air filter

１．
With an adjuster, adjust the free play at thethrottle grip to be approximately 5 mm.
After the adjustment, cover the adjuster with arubber adjuster cover.

As the sponge element is used in thesupplied filter, the filter is easy to wash. Whenthe element has got dirty, clean the elementin the following manner.
(To this product, never apply chemicals likefilter cleaner or filter oil sold on the market.
If such chemicals are used, the element
could deteriorate.)

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Caution: Apply the specified torque.
Torque:7 N・m (0.7 kgf・m)

２．Remove the top cover of the supplied
carburetor, and pull out the spring and throttle
valves.
First, pass the throttle cable through the cablecap which is made of rubber and attached tothe carburetor. Then pass the inner cablethrough the top cover of the carburetor. Thenplace the spring, and compressing it, attach itto the throttle valve.
３．Route the throttle cable across the frame.
And mesh the notch on the throttle valve withthe throttle stop screw to install the throttle
valve onto the carburetor.

２．Snap the throttle a few times to make sure thatthe throttle moves smoothly without sticking andthat the throttle valve is fully open.
Also check that the throttle has free play evenwhen a steering handle is turned all the way tothe right or to the left.
３．Reinstall back the fuel tank and seat onto themotorcycle, and fix the throttle cable bypassing it through the cable guide on the leftThrottle stop screw

４．Place the carburetor gaskets in-between thecarburetor and intake manifold, and install thecarburetor with a 6x25 socket cap screw
and a 6mm lock nut.
Caution: Apply the specified torque.
Torque:10 N・m (1.0 kgf・m)
５．After installing the carburetor, check that
there is space between the carburetor float
chamber and cylinder head. If the float
chamber is interfering with the cylinder head,first check that the gaskets are certainlyinstalled. Then loosen for now
carburetor-holding screws.
And holding the carburetor at a location
where it does not interfere with the float
chamber, tighten up the carburetor-holding
screws again.
６．If the rib in the middle of the frame and air
filter cover interferes with each other after
the installation, then scrape off the portion on
the frame which interferes with the filter
cover.
(Be careful not to scrape off more thanneeded. So, do the work with the greatest
care.)

１．Detach the air filter from the vehicle andremove dust and dirt on the element surface.
Work with your hands protected lest you
should have your hands cut by the coveredges.
２． Prepare cleaning liquid out of mild detergent
available on the market, diluting it with water,and soak the filter in the cleaning liquid toclean the element.
(Never scrub the element with a hard brushor rub the element hard.
Otherwise, the element will be damaged.)
３．Let the running tap water into inside of thePYside of the tank.

Notch

How to perform maintenance ofelement to thoroughly rinse the cleaning
liquid out of the element.
４．After rinsing off the cleaning liquid, dry theelement. And place it in the airy shade to let it
dry naturally. In case you use compressed
air, let the air into inside of the element withlow pressure to blow off the moisture.

４．Connect the fuel tank and carburetor with thesupplied fuel hose.
And open the fuel cock to check each section
for oil leakage.
(Do not leave the cock open for a long time.)

５．Pull the choke lever to start the engine.
Gradually push the lever back and warm up theengine till the revolution becomes smooth, andfinally push the lever back to its original
location. In case, after the warm-up of theengine, your motorcycle does not run idle or theidling engine speed is high, adjust the settingwith the throttle stop screw.
６．If you have adjusted the throttle stop screw,
check again the free play at the throttle grip.
７．Reinstall back the right and left side covers.
８．Do the setting with great care to meet theindividual engine and other conditions in a safe
place.
‑3‑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
2021.2.10

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:

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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 overheats somewhat.
・The engine starts working well If you use the choke,.
・The engine does not accelerate well. (No smooth acceleration)

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

・Revolutions change, generating weak power.
・The plug burns white.

※ 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 thelocation of the E-ring moves down from the 1st to the 5th groove.

2段目
2nd groove

3段目
3rdgroove
4段目
4thgroove

1段目
1stgroove○Main jet (The throttle position at 3/4 - 4/4)

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5段目
5thgroove

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, thedenser the mixture ratio becomes.
In view of the engine and muffler specifications, select the most appropriate main jet to get the highest revolutions.

○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.
・ 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 runningat slow speed.
・When the engine revolves up unevenly, the pilot jet number is too small. (At idle)
・ When the motorcycle belches black exhaust gas and produces heavy exhaust sound, the pilot jet number is too big. (At idle)
・After replacing the 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 highestrevolutions.

●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 andprices are subject to change without prior notice.
◎ This manual should be retained for future reference.
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
Aug./20/ 09