Service Procedures:

(If Chart 1 indicates that the choke chamber and carburetor insulator should be applied, proceed with step 1. If not, to to step 19.)

I. Choke chamber, carburetor insulator



1. Perform idle mixture inspection per service manual. If CO% is less than 1.5 %, then remove idle mixture screw plug when the carburetor is removed during the following procedure.

2. Remove air cleaner.

3. Disconnect fuel hose, vacuum hoses, throttle cable, and carburetor wiring harness, and remove the carburetor assembly.

4. Disconnect vacuum hoses A and B from the choke chamber.



5. Disconnect choke connecting rod from choke chamber.

6. Remove choke chamber screws D. (see Figure 2) Remove choke heater wire from carburetor electrical connector by depressing locking tabs on terminal.
7. With choke chamber loose, remove accelerator pump rod from throttle lever. Remove choke chamber.

8. With compressed air, blow passages, castings, and parts until they are dry.

9. Remove float from the former choke chamber and install it on the new choke chamber. Check float level adjustment as follows:



A. Turn down choke chamber to allow float to come into contact with needle valve, and measure "H", (Figure 3).
When "H" is approximately 0.47 in., the top float position is correct. It can be adjusted by bending the float seat. Upon completion of the adjustment, check fuel level with attached level gauge.

B. Adjust bottom float position so that clearance "h" between float seat and needle valve stem is 0.051 to 0.067 in., when float is fully raised. Bend float stopper as required.

C. After adjustments in steps A and B, make sure that when fuel is delivered to the float chamber, the fuel level is maintained at fuel level mark.
10. Install new choke chamber gasket.

11. Install accelerator pump rod from throttle lever. Install new choke chamber and tighten screws.

12. Connect choke connecting rod to choke chamber.

13. Connect vacuum hoses A and B shown in (Figure 1).

14. Install choke heater wire in the carburetor electrical connector.

15. Check catalyst warm-up throttle opener.

Gap between throttle valve and carburetor body:
Manual Transmission .072 + .005 in.

Automatic Transmission: .077 + .005 in.



16. Fast idle cam adjustment.

A. Disconnect the vacuum hose from the vacuum break diaphragm.
B. Push the vacuum break stem in, as shown, and install a blind plug to hold the vacuum break stem in this position.

C. Turn the throttle lever to the wide open position, then release.

D. Adjust clearance "A": between primary throttle valve and inner carburetor wall by turning fast idle adjusting screw.



(see illustration).

Clearance "A":

M/T 0.08 +/- 0.07mm

(0.0315 +/- 0.0028 in.)

A/T 1.07 +/- 0.07mm

(0.0421 +/- 0.0028 in.)
E. Remove blind plug and reinstall the vacuum hose removed in Step A.

17. If applicable remove old carburetor insulator and install new countermeasure insulator.

18. Reinstall carburetor and connect fuel hoses, vacuum hoses, throttle cable, and carburetor wiring harness.