FUEL SYSTEM. Table of Contents. Specifications. Special Tools. Section 3B Carburetor. 950 ± 50 rpm 850 ± 50 rpm

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1 Tle of Contents FUEL SYSTEM Setion 3B Cruretor CARBURETOR Speifitions B-1 Speil Tools B-1 Cruretor B-2 Cruretor B-3 Intke B-4 Intke B-5 Cruretor Ajustments B-6 Ile Spee B-6 Linkge B-6 Speifitions Choke B-9 Cruretor Removl B-11 Cruretor Disssemly B-13 Clening/Inspetion/Repir B-15 Cruretor Ressemly B-16 Flot Height Mesurement B-18 Cruretor Instlltion B-19 Eletri Choke Moels Instlltion B-19 3 B CARBURETOR Ile rpm (Out Of Ger) Ile rpm (In Forwr Ger) Wie Open Throttle rpm (WOT) Stnr Moel Rnge Boensee Moel Rnge Stnr Moel Min Jet Size 9.9 hp 15 hp Pilot Jet Boensee Moel Min Jet Size 9.9 hp 15 hp Pilot Jet Flot Height 950 ± 50 rpm 850 ± 50 rpm #68 #104 #45 #68 #103 # ± 0.04 in. (15.5 ± 1.0 mm) Speil Tools 1. Cruretor Sle P/N R1 AUGUST 1998 Pge 3B-1

2 Cruretor Pge 3B R1 AUGUST 1998

3 Cruretor TORQUE REF. NO. QTY. DESCRIPTION l-in. l-ft Nm 1 CARBURETOR (15) 1 CARBURETOR (9.9) 1 1 CARBURETOR (9.9 BODENSEE) 1 CARBURETOR (15 BODENSEE) 2 2 SCREW (M4x10) COVER 4 1 GASKET 5 1 THROTTLE SCREW 6 1 SPRING-Pilot Ajusting 7 1 SCREW (M4x5) Drive Tight 8 1 PLATE 9 1 SCREW (M3x5) Drive Tight 10 1 PILOT JET (#45) PLUG MAIN NOZZLE (15) MAIN NOZZLE (15 BODENSEE) MAIN NOZZLE (ALL 9.9) O RING 1 MAIN JET (#104) (15) MAIN JET (#103) (15 BODENSEE) MAIN JET (#68) (ALL 9.9) SCREW (M4x5) NEEDLE VALVE 17 1 FLOAT 18 1 FLOAT PIN 19 1 GASKET 20 1 FILTER 1 FLOAT BOWL ASSEMBLY (15) 21 1 FLOAT BOWL ASSEMBLY (9.9) 22 1 RETAINING RING 23 1 CAP 24 1 SEAL 25 1 DIAPHRAGM SPRING 27 1 COVER 28 3 SCREW (M4x8) DRAIN SCREW (M4x5) GASKET 31 1 DRAIN SCREW (M5x6) GASKET Not Inlue W/ 9.9 Bowl 33 4 SCREW (M4x12) CHECK VALVE (15) 35 1 SEAL (BODENSEE) R1 AUGUST 1998 Pge 3B-3

4 Intke Stroke Outor Oil ( A12) Pge 3B R1 AUGUST 1998

5 Intke TORQUE REF. NO. QTY. DESCRIPTION l-in. l-ft Nm 1 1 INTAKE MANIFOLD 2 1 GASKET 3 2 DOWEL PIN 4 4 BOLT (M6 x 40) INSULATOR 6 2 GASKET 7 1 O RING 8 1 SILENCER 9 DECAL-Wrning, High Voltge 10 1 PLATE 11 2 COLLAR 12 2 BOLT (M6 x 100) HOSE R1 AUGUST 1998 Pge 3B-5

6 Cruretor Ajustments Ile Spee NOTE: Before justing the ile spee mke sure the throttle link ro hs een properly juste. 1. Mesure the ile spee using the proeure elow, just if neessry: Strt engine n llow it to wrm up. Atth thometer to the sprk plug le of yliner #1. Mesure ile rpm with outor in neutrl. Turn throttle stop srew in iretion A or B until the speifie ile spee is otine. NOTE: Turning throttle stop srew in () will inrese ile spee while turning srew out () will erese spee. Ile rpm (Out Of Ger) 950 ± 50 RPM Linkge REMOTE CONTROL MODELS 1. Connet throttle linkge n seure with srew. NOTE: Linkge shoul exten 0.28 in. (7 mm) eyon rrel. Over-tightening srew my mge throttle linkge. -Throttle Linkge in. (7 mm) Length -Srew Pge 3B R1 AUGUST 1998

7 TILLER HANDLE MODELS (SIDE SHIFT SHOWN) 1. Turn ile spee srew ounterlokwise until srew is not touhing throttle shft rm. -Ile Spee Srew -Throttle Shft Arm 2. Instll throttle linkge on pulley n throttle rrel. -Throttle Linkge -Throttle Brrel -Pulley 3. Chek to mke sure throttle linkge is hs free movement etween throttle rrel n pulley. NOTE: The throttle rm shoul remin sttionry while heking for free movement of throttle linkge. -Throttle Brrel -Pulley -Throttle Arm R1 AUGUST 1998 Pge 3B-7

8 4. Move throttle linkge forwr until linkge omes to rest on the pulley oss. -Throttle Linkge -Pulley Boss 5. Tighten srew on throttle rrel to seure linkge. NOTE: Over-tightening srew my mge throttle linkge. NOTE: Chek linkge for free movement on pulley. Verify throttle shft rm in not stiking n returns to ile position. -Srew -Linkge 6. Verify throttle rm oes not hit the full throttle stop t wie open throttle. Gp etween stop n throttle rm shoul e no more thn 0.1 in. (2.54 mm). -Throttle Stop -Throttle Arm -Approximtely 0.1 in. (2.54 mm) Gp Pge 3B R1 AUGUST 1998

9 7. Turn ile spee srew in (lokwise) until it touhes the throttle shft rm, then turn n itionl 1/2 turn for initil setting. Choke -Ile Spee Srew -Throttle Shft Arm 1. Route hoke le through le rket n instll retining ring. -Choke Cle -Retining Ring 2. Set the hoke le to the off position (le fully pushe in). -Choke Cle R1 AUGUST 1998 Pge 3B-9

10 3. Set hoke shutter to the off position (shutter lever rotte fully ounterlokwise). 4. Thre the ll soket en on shft until ll soket ligns with ll on ruretor. Snp soket onto ll. NOTE: Verify hoke goes to full hoke with le pulle out n returns to off position with le pushe in. -Three Bll Soket -Bll -Shutter Lever Pge 3B R1 AUGUST 1998

11 Cruretor Removl 1. Remove throttle linkge from ruretor rrel. CARBURETOR -Brrel -Throttle Link 2. Remove hoke linkge (tiller hnle moels only). -Choke Linkge 3. Remove j-lips. 4. Disonnet rether hose from ir intke n rether over. -J-Clips (2) -Brether Hose -Air Intke -Brether Cover R1 AUGUST 1998 Pge 3B-11

12 5. Remove olts. 6. Seprte intke/ruretor ssemly from powerhe. -Bolts M8x40 (4) -Dowel Pin (2) -Gsket-Mnifol (Disr) Remove ir intke olts. 8. Seprte intke/mnifol omponents from ruretor ssemly. g i e g h f -Bolts-Air Intke M6x76 (2) -Spers (2) -Plte -Air Intke e-o-ring (Disr) f-cruretor Assemly g-gsket (2) (Disr) h-insultor i-mnifol Pge 3B R1 AUGUST 1998

13 Cruretor Disssemly CARBURETOR 1. Remove rin srew. NOTE: Use n eptle ontiner to hol gs when rining flot owl. 2. Remove flot owl. 3. Remove over. g h i f e -Drin Srew-M5x6 -Gsket-Drin Srew -Srews (4)-M4x12 -Flot Bowl e-vlve f-gsket-flot Bowl g-srew(2)-m4x10 h-cover i-gsket 4. Remove flot ssemly. -Srew-M4x5 -Pin -Neele Vlve -Flot Assemly R1 AUGUST 1998 Pge 3B-13

14 5. Remove jets n nozzle. f g e -Min Nozzle -O-Ring -Min Jet -Pilot Jet e-sel Cp f-plte g-srew-m3x5 6. Remove iphrgm n filter. g h j k f i e -Filter -Srew-M4x5 -Gsket-Drin Srew -Srews (3)-M4x8 e-bse f-spring g-ring h-cp i-diphrgm j-plunger k-o-rings (2) Pge 3B R1 AUGUST 1998

15 Clening/Inspetion/Repir CARBURETOR 1. Inspet ruretor oy for rks/mge/ontmintion. Reple/len s neessry. NOTE: Use petroleum se solvent for lening. Blow out ll pssges with ompresse ir, never use wire. 2. Inspet jets n nozzle for ontmintion. Reple if neessry. -Min Jet -Pilot Jet -Vlve -Min Nozzle 3. Inspet neele vlve for wer. Reple if neessry. NOTE: Chek tip of neele vlve for wer. 4. Inspet flot for rks/mge. Reple if neessry. 5. Inspet iphrgm, o-rings n gskets for mge. Reple if neessry. 6. Inspet filter for ontmintion/mge. Clen/reple if neessry R1 AUGUST 1998 Pge 3B-15

16 Cruretor Ressemly 1. Instll iphrgm n filter. e k f g h i j -O-Rings (2) -Plunger -Diphrgm -Cp e-ring f-spring g-bse h-srews (3)-M4x8 i-gsket-drin Srew j-srew-m4x5 k-filter 2. Instll jets n nozzle. e f g -Plte -Srew-M3x5 -Pilot Jet -Sel Cp e-min Nozzle f-o-ring g-min Jet Pge 3B R1 AUGUST 1998

17 3. Instll neele vlve onto flot hinge. CARBURETOR -Flot -Neele Vlve -Pin Instll flot ssemly. -Flot -Pin-M4x5 -Srew R1 AUGUST 1998 Pge 3B-17

18 Flot Height Mesurement 1. Mesure flot height s shown, if out of speifition reple. P/N Cruretor Flot Height 0.61 ± 0.04 in. (15.5 ± 1.0 mm) or 36/64 in. - 41/64 in. 2. Instll rin srew, flot owl n over. e h i f g -Gsket -Cover -Srew (2)-M4x10 -Vlve e-gsket-flot Bowl f-flot Bowl g-srews (4)-M4x12 h-gsket-drin Srew i-drin Srew-M5x6 Pge 3B R1 AUGUST 1998

19 Cruretor Instlltion Eletri Choke Moels Instlltion 1. Assemle solenoi omponents s shown. CARBURETOR f e -Grommet -O-ring -Hook -Solenoi e-brket f-srews M5x8 - Torque to 30 l-in. (3.4 Nm) 2. Instll solenoi to ruretor ssemly. Push grommet over pin n seure spring to ruretor with O-ring. -Solenoi Assemly -Grommet -O-ring Seure solenoi rket to powerhe with two (2) olts M6x16. Connet BLUE to YEL- LOW/BLACK n BLACK le to BLACK le from remote ontrol Bolts M6x16 (2) - Torque to 70 l-in. (8 Nm) -Solenoi Brket R1 AUGUST 1998 Pge 3B-19

20 1. Assemle intke/mnifol omponents to ruretor ssemly. 2. Seure ir intke with olts. h e i g -Mnifol -Gsket (2) (New) -Insultor -Cruretor Assemly e-o-ring (New) f-plte g-spers h-air Intke i-bolts (2)-M6x 100 f Cruretor Mounting Bolts 88 l-in. (10 Nm) Pge 3B R1 AUGUST 1998

21 3. Instll intke/ruretor ssemly onto powerhe. CARBURETOR -Gsket-Mnifol (New) -Dowel Pin (2) -Intke/Cruretor Assemly -Bolts (4) M6x Mnifol Mounting Bolts 70 l-in. (8 Nm) 4. Instll j-lips. 5. Connet rether hose to ir intke n route hose through j-lips. -J-Clips (2) -Brether Hose R1 AUGUST 1998 Pge 3B-21