Removal and Disassembly

Carburetor R & R:

REMOVAL:
1. Disconnect battery ground cable.
2. Remove air cleaner.
3. Disconnect the throttle cable from carburetor.
4. Disconnect the vacuum hoses from carburetor.
5. Disconnect electrical connectors for solenoid valves and Throttle Position Sensor (TPS). Using a screwdriver lift up the stopper portion and remove the terminals from the back of the connector.

Throttle Position Sensor Terminal ID:

6. Place a container under the fuel fittings to catch any fuel that may be trapped in the lines.
7. Disconnect the fuel hoses from the carburetor inlet.
8. Remove carburetor mounting bolts and carefully remove the carburetor from engine.
NOTE: Hold carburetor level to avoid spilling fuel from fuel bowl.

DISASSEMBLY:

Carburetor Overhaul:

Throttle Return Spring Removal:

1. Remove the throttle return spring from the throttle lever. Unscrewing the two screws remove the throttle return spring bracket.

Dash Pot Rod Removal:

2. Remove the dash pot rod from the free lever.

Fuel Connector Bracket Removal:

3. Unscrewing the two screws, remove the bracket off of the fuel connectors.

Delay Valve Hose Removal:

4. Pull the hose, with the delay valve, off the nipple of the choke breaker.

Float Chamber Cover Screws Removal:

5. Remove the float chamber cover "B" screw for later removal of the throttle body.
6. Remove the "A" screws to remove the float chamber cover from main body.

Float Chamber Cover Removal:

7. To remove the float chamber cover assembly, insert a screw driver blade between the enrichment cover and the float chamber cover, as illustrated. Pry lightly while lifting up slowly. Do not apply excessive force.

Float Pivot Pin Removal:

8. Invert the cover assembly and remove the pin, then remove the float and needle valve.

Needle Valve Seat Removal:

9. Using flat blade screwdrivers, pry up the needle valve seat at both edges to remove. Use care not to damage the float chamber cover when prying up the needle valve seat.

Feedback Solenoid Valve Retainer Removal:

10. Remove the retainer for the feedback solenoid valve (FBSV).

Feedback Solenoid Terminal ID:

11. Using a screwdriver lift up the stopper portion and remove the two terminals from the back of the connector.
NOTE: Unless the terminals are removed from the connector, the feedback solenoid valve cannot be removed from the float chamber cover.

Feedback Solenoid Removal:

12. Pull out the FBSV from the float chamber cover.

Slow Cut Solenoid Removal:

13. Remove the retainer and pull out the slowcut solenoid valve.

Slow-cut Solenoid Valve Terminal ID:

14. Using a screwdriver lift up the stopper portion and remove the two terminals from the back of the connector.

Bimetal Assembly Removal:

15. To remove the bimetal assembly, grind away the head of the two rivets holding the bimetal assembly then remove the screw.
16. Remove the plate and the bimetal assembly.

Connector Disassembly:

17. Using a screwdriver lift up the stopper portion and remove the terminal from the back of the connector.

Bowl Vent Valve (BVV):

18. Remove the three screws attaching the [1][2]bowl vent valve cover to the float chamber.
19. Remove the plastic vent housing, housing cover and the two springs. Be careful not to misplace the two small springs positioned on either side of the plastic vent housing.

Bowl Vent Valve Diaphragm Shaft Removal:

20. Remove the [1][2]bowl vent valve diaphragm shaft. Carefully pull the diaphragm out of the float chamber cover so that the rubber vent seal slides off the diaphragm shaft.

Mixture Control Valve Assembly Removal:

21. Remove the three screws attaching the Mixture Control Valve (MCV) assembly. Remove the MCV assembly.

Choke Vacuum Breaker Assembly Removal:

22. Remove the three screws attaching the choke vacuum breaker cover, then remove the choke break cover, springs, diaphragm and linkage assembly.

Choke Bracket Removal:

23. Remove the choke bracket.

Choke Opener Removal:

24. Unscrewing the four screws, remove the choke opener.
25. Remove the pilot jets and main air jet, use a screwdriver that is an exact fit for their slot and work carefully to prevent damage.

Carburetor Disassembly:

26. Carefully lift and swing up the rollover device weight from the bottom of the float chamber, then use a magnet to remove the roll-over steel ball. Remove the float chamber gasket and pour the remaining fuel contained in the float chamber into a container.

Accelerator Pump Check Ball Removal:

27. Invert the chamber and remove the accelerator pump outlet check ball and weight located at the gasket surface.

Throttle Body Removal:

28. Remove the remaining screw and separate the float chamber from the throttle body.

Main Jet Removal:

29. Remove the main jets, use a screwdriver that is an exact fit and work carefully to prevent damage to the enrichment housing on the float chamber cover.

Enrichment Valve Cover Removal:

30. Remove the three screws attaching the enrichment valve
31. Remove the cover, spring and diaphragm.
32. Unscrew the enrichment valve from the housing.

Enrichment Valve Check Ball Removal:

33. Using a screwdriver, loosen the enrichment jet and take out the spring and ball from the enrichment jet valve.
CAUTION: The valve has many small parts. Do not lose them.

Accelerator Pump Removal:

34. Remove the four screws attaching the accelerator pump cover to the float chamber. These four screws have thread sealant applied to them and may present some additional difficulty with removal.

Accelerator Pump Assembly:

35. Remove the accelerator pump cover, diaphragm, spring, pumpbody and gaskets.

Secondary Throttle Diaphragm Removal:

36. Remove the clip and outside washer on the secondary throttle shaft and slide the diaphragm spring link off the throttle shaft.
37. Remove the two screws attaching the diaphragm bracket to throttle body and remove the secondary throttle diaphragm.

Throttle Position Sensor Removal:

38. Using a 10 mm wrench, remove the nut attaching the accelerator pump lever to the throttle shaft. With an impact driver, remove the two screws attaching the throttle position sensor to the throttle body.
39. Remove the E clip holding the throttle position sensor onto the throttle shaft.

Concealment Plug Removal:

40. For removal of the concealment plug, clamp carburetor base plate in a vice and drill a (5/64 in.) pilot hole in the casting surrounding the idle mixture adjusting screw (MAS) then redrill the hole to (1/8 in.)
41. Insert a blunt punch into the hole and drive out plug.