DENI 18 Carburetor Kit Instruction Manual

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Item No ：０３−０５−００５９ (Carburetor Kit)
：０３−０２−０５８ (Manifold Kit)
Fit ： TT-R50E

Safety Precautions for Use

○ Thank you for purchasing our “DENI 18 Carburetor Kit” (for TT-R50E). Please strictly follow the following instructions in installing and using the Kit.
○Before installing the Kit, please be sure to check the Kit contents. Should you have any questions about the Kit, please contact your local motorcycle
dealer.
○Please note that this Kit is for installation with S-Stage Kit for TT-R50E and that it cannot be used with a standard engine or cannot be used in any other
models of motorcycles than those mentioned in the top right-hand corner of this page.
○The installation of this product requires processing to a stopper on the throttle pipe. And please take note that this processing disables the use of the
axle limiter.
○ NEVER run your motorcycle in the rain, which please take note.

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○ Carburetor's setting varies according to parts used, natural phenomena, or other factors. Please adjust the setting to meet your own requirements
based on the supplied jet as a benchmark for the setting.
○ For the installation of this product, a stay on the frame needs to be cut off.

◎ Please note that, in some cases, the illustrations and photos may vary from the actual hardware.

The following show the envisioned possibility of injuries to human bodies and property damage as a result of disregarding the
Cautions following cautions.
・Work only when the engine and muffler are cool at below 35 degrees Celsius. If you do the work when the engine and muffler are not cool,
you will get burned.
・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.)
・Always use a hose clip to connect the hose firmly to the carburetor.
・Never look into the carburetor's intake pipe carelessly when the engine is running. Flames could spurt by the spitting-back of gasoline or backfire,
which involves danger.
・Setting of a carburetor varies according to the natural phenomena like the weather, temperatures and barometric pressure, combination of parts
used and the vehicle itself. Arrange the setting, in a safe place with sufficient care, to match each vehicle.
・Before riding, always check every section for slack in parts and oil leak. When you notice something abnormal with your motorcycle while riding,
immediately stop riding and park your motorcycle in a safe place to check what has gone wrong.

The following show the envisioned possibility of human death or serious injuries to human bodies as a result of disregarding the
Warnings following warnings.
・Those who are technically unskilled or inexperienced are required not to do the work.
(Possible parts breakage may lead to overturning of your motorcycle or accidents.)
・Before riding, check every part of your machine for the slack in parts or gasoline leakage. When you notice something abnormal with your
motorcycle while riding down a road, immediately stop riding and park your motorcycle in a safe place.
(Otherwise, the abnormality could lead to accidents.)
・Always drive the engine in a well-ventilated place, and do not switch the engine on in an airtight place.
(Otherwise, you will suffer from carbon monoxide poisoning.)
・Before starting the work, stand your bike securely.
(Otherwise, your motorcycle could overturn and injure you.)
・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 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.
◎ 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.
◎ This manual should be retained for future reference.

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 Kit includes:
１

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８

４ ７
３

５
６

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９

No. Part Name Qty Repair Part Item No. in packs of

1 Carburetor assembly １ 03-03-0061 1
※2 Inlet pipe １ 17111-5DV-T00 1
※3 Inlet pipe gasket １ 91301-181-T01 2
※4 Carburtor gasket １ 16201-GEY-T01 2
※5 Socket cap screws, 6 X 20 ４ 00-00-0043 10
6 Main jet, #85 １ 00-03-0041 1
※7 Throttle cable, 660 mm １ 17910-5DV-T00 1
8 High flow filter, bent at 45 degrees １ 03-01-1104 1
※9 Insulation lock １ 00-00-0202 10
Parts of Nos. with an asterisk are components of Manifold Kit.
∴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.

● Removal of stock parts:
１．Removal of exterior parts:
◇Turn off a fuel cock, and pull out a fuel
hose from the cock.
◇ Unfasten two bolts on the reverse side of
seat and remove the seat.
∼ Installation Instructions ∼
◇ As shown in the photo below, unfasten right
and left bolts & washers holding the fuel tank
and frame, and a band at the rear side of the
fuel tank in order to demount the fuel tank.
Bolts & washers
２．Removal of carburetor:
◇ Unfasten a set of engine mount bolt and
nut, and two bolts to detach an engine
bracket.

Band

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◇Unfasten a bolt on the air-cleaner-box stay and
loosen a band on the joint in order to remove the
air cleaner box.
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◇ Disconnect a heater lead cord from the
carburetor and insulate the cord with a vinyl
tape.
Cord
◇ Detach a choke lever from the frame.
◇Remove two bolts holding the cylinder head
and inlet pipe.
◇ Remove the carburetor and axle wire from the
vehicle.
３．Removal of throttle cable: ● Carburetor installation:
◇ Unfasten two screws, and detach the switch
１．Throttle cable installation:
and grip assemblies from the steering handle.
◇ Remove the stopper on the grip assembly by
processing it.
Stopper
Screws
◇ Detach a throttle cable from the switch
assembly.
● Preparation for installing hardware
◇ Attach a supplied throttle cable to the switch
assembly.
◇ Connect the inner cable to the processed grip
assembly, and attach the switch assembly to
the steering handle with two screws.
２．Carburetor installation:
◇ Unfasten two screws to remove the float
chamber.
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to the body: Float chamber
◇ As a stay on the frame interferes with an air
cleaner, cut off the stay.
Screws
◇Remove a main jet from the jet holder, and then
install a supplied main jet.
Jet holder
Main jet
◇ As the cord interferes with the carburetor,
attach the ignition coil on the opposite side.
◇ Install the float chamber to the carburetor with
two screws.
◇ Place a gasket between cylinder head and
inlet pipe, and tighten it with socket cap screws.
Place a gasket between carburetor and inlet
pipe, and tighten it with a socket cap screw.
Caution : Be sure to follow the specified
torque.
Torque: 10 N･m (1.0 kgf･m)
6x20 screws
Gaskets
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◇ Remove a top cap from the carburetor.
And pull out a spring and throttle valve.
And attach all of these 3 parts to the throttle
cable.
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◇ Fix the throttle valve to the carburetor by
aligning a notch on the throttle valve with the
throttle stop screw. Align the convex section
on the top cover with the concave section on
the carburetor.
※ Snap the throttle a few times to check how the
throttle valve opens and closes.
Notch
Throttle stop screw
◇Adjust the throttle cable so there is free play of
about 5 mm at the throttle grip.
◇ Dispose of the blowby gas from the
crankcase by yourself.
２．Installation of exterior hardware:
◇ Fix the engine bracket with a set of engine
mount bolt and nut, and two bolts.
Caution : Be sure to follow the specified
torque.
Torque: 30 N･m (3.0 kgf･m)
◇ Attach the fuel tank to the frame, fixing the
right and left sides with bolts, and the rear side
with a band.
Caution : Be sure to follow the specified
torque.
Torque: 7 N･m (0.7 kgf･m)
◇ Install the seat to the frame with two bolts.
Caution : Be sure to follow the specified
torque.
Torque: 7 N･m (0.7 kgf･m)
◇ Attach the fuel hose to the cock.
Maintenance instructions of air
cleaner:
It is easy to perform the maintenance in case the
supplied filter is a high flow filter. And when the
element is stained, perform the maintenance as fol-
lows:
(Please never use chemical products like filter cleaner
or filter oil available on the market. Otherwise, the
element may deteriorate in some cases.)
１．Detach it from the bike and remove large dust
on the element surface.
２．Prepare cleaning liquid out of mild detergent
available on the market diluting it with water,
and soak the filter in the cleaning liquid to clean
the element.
(Never scrub the element with a hard brush or
rub the element hard. Otherwise, the element
will be damaged.)
３．Let the running water into inside of the element
to thoroughly rinse the cleaning liquid out of the
element.
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４．After rinsing off the cleaning liquid, dry the
element.
Mop the element with a waste cloth to remove
the moisture, and dry it in the airy shade, letting
it dry naturally.
In case you use compressed air, let the air into
inside of the element with low pressure to blow
off the moisture.
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
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 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:

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・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.

※ 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.

3段目

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3rd groove
2段目
2nd groove 4段目
4th groove
1段目
1st groove 5段目
5th 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 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 running
at 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 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 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.

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