Reassembly and Installation
REASSEMBLYPerform reassembly in reverse of disassembly procedure, paying special attention to the following items:
1. Clean all parts before reassembly.
2. Check for smooth operation of throttle and choke linkage. If the operation is not smooth, clean all of the components. Re-check after cleaning. If the operation is still not smooth, replace the defective components.
3. Check to be sure that no restrictions are in the air passages and fuel passages.
4. When replacing a main or a pilot jet, the old jet and the new jet must be of the same size, because the jet is selected after exact flow measurement by factory.
5. Do not reuse the rings and gasket. Replace them with new ones at every reassembly.
NOTE: Following are several points that require special attention during reassembly.
Main Jet Size Symbol Location:
Secondary Jet Size Symbol Location:
1. Make sure that correct jets are installed at correct positions. Note the size symbol stamped on each jet for identification.
2. On the bimetal assembly perform the following:
Bimetal Assembly Installation:
(a) Fit the bimetal end over the choke valve lever.
(b) Install the plate and temporarily tighten the screw.
Bimetal Assembly Initial Alignment:
(c) Align the mating marks.
Rivet Installation:
(d) Set the rivet as illustrated.
Bimetal Assembly Rivet Installation:
(e) While keeping the mating marks aligned, install the bimetal assembly with a hand riveter or similar tool.
(f) Tighten the remaining screw.
Bimetal Assembly Terminal Installation:
(g) Install terminal into the connector at the correct position.
Accelerator Pump Assembly:
4. When reinstalling the accelerator pump assembly, apply thread sealant to the screws and be sure the pump body, gasket and cover are properly positioned.
LINKAGE INSPECTIONS AND ADJUSTMENTS
Inspect the following linkages for proper operation and adjustment. Correct all mechanical malfunctions and clearance settings before reassembly
LINKAGE INSPECTIONS AND ADJUSTMENTS
Inspect the following linkages for proper operation and adjustment. Correct all mechanical malfunctions and clearance settings before reassembly
FAST IDLE OPENING
Fast Idle Opening Initial Setting:
1. Set the lever on the mark (scribed line) of the fast idle cam.
Throttle Bore Clearance Initial Setting:
2. Measure the primary valve to throttle bore clearance.
OPENING CLEARANCE (DRILL DIAMETER):
M/T: 0.037 in. (0.93 mm)
A/T: 0.040 in. (1.02 mm)
3. If the clearance is out of adjustment, adjust using the fast idle adjustment screw.
UNLOADER OPENING
1. Lightly press the choke valve with a finger to fully close it.
Choke Valve Clearance Check:
2. Starting with the choke valve in this position, fully open the throttle valve and measure the choke valve to choke bore clearance.
CLEARANCE: 0.075 - 0.083 in.
(1.9 - 2.1 mm)
Choke Valve Clearance Adjustment:
3. If the clearance is out of specification, bend the throttle lever, at the illustrated portion, to adjust the clearance to the standard value.
CHOKE BREAKER
1. Lightly press the choke valve with a finger to fully close it.
Choke Valve Clearance Check:
2. Push the choke breaker rod toward the diaphragm and measure the choke valve to choke bore clearance.
CLEARANCE:
1st stage: 0.055 - 0.063 in.
(1.4 - 1.6 mm)
2nd stage: 0.114 - 0.122 in.
(2.9 - 3.1 mm)
Choke Breaker Rod Adjustment:
3. If the clearance is out of specification, adjust by bending the throttle lever as illustrated.
INSTALLATION
1. Inspect the mating surfaces of carburetor and intake manifold for burrs or other damage.
2. Place a new carburetor gasket on the intake manifold surface.
3. Carefully place the carburetor on intake manifold.
4. Install the carburetor mounting bolts and tighten alternately (a little at time) to compress the carburetor gasket evenly. The bolts must be drawn down tightly to prevent vacuum leakage between the carburetor and intake manifold.
5. Connect the throttle cable, vacuum hoses and fuel hoses.
6. Check carefully for worn of loose vacuum hose connections. Replace any suspect hoses.
7. Check to be sure the choke valve opens and closes fully when operated.
8. Check the throttle operation to see that full throttle is obtained.
9. Install air cleaner. The air cleaner should be cleaned or replaced at this time to ensure proper carburetor performance.
10. Connect battery cable.
CAUTION: The practice of priming an engine by pouring gasoline into the carburetor air horn should be strictly avoided. Cranking the engine and priming, by depressing the accelerator pedal several times, should be adequate.
11. Set carburetor idle speed, mixture adjustment and adjust the throttle cable. Refer to ADJUSTMENT PROCEDURES.