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 Intke B-4 Cruretor Ciruits B-6 Ile Ciruit B-6 Off-Ile Ciruit B-7 High Spee Ciruit B-8 Aelertion Ciruit B-9 Choke iruit B-10 Cruretor Ajustments B-11 Speifitions Ile Spee B-11 Linkge B-11 Choke B-14 Aelertor Ajustment B-15 Cruretor Removl B-16 Cruretor Disssemly B-18 Clening/Inspetion/Repir B-20 Cruretor Ressemly B-22 Flot Height Mesurement B-25 Cruretor Instlltion B-26 Eletri Choke Moels Instlltion B-26 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 # ± 1.0 mm (0.61 ± 0.04 in.) Speil Tools 1. Cruretor Sle (Otin Lolly) R02 SEPTEMBER 2002 Pge 3B-1

2 Cruretor Pge 3B R02 SEPTEMBER 2002

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 26 1 SPRING 27 1 COVER 28 3 SCREW (M4x8) DRAIN SCREW (M4x5) GASKET 31 1 DRAIN SCREW (M5x6) GASKET Not Inlue with 9.9 Bowl 33 4 SCREW (M4x12) CHECK VALVE (15) 35 1 SEAL (BODENSEE) R02 SEPTEMBER 2002 Pge 3B-3

4 Intke Stroke Outor Oil Pge 3B R02 SEPTEMBER 2002

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 R02 SEPTEMBER 2002 Pge 3B-5

6 Cruretor Ciruits Ile Ciruit m e f l k h ÄÄ g j i - Air Blee Inlet - Flot Bowl Vent Inlet - Ile Air Blee Restritor - Off-Ile Dishrge Port e - Ile Dishrge Port f - Throttle Vlve g- Inlet Filter h- Fuel Inlet i - Bowl Drin j - Min Jet k - Pilot Jet l - Choke Vlve m- Air Flow As the engine rottes, the piston trvel moves wy from the open intke vlve. This movement retes low pressure re ehin the throttle vlve. Atmospheri pressure pushes ir through the ruretor throt (venturi), pst the throttle vlve n into the low pressure re insie the intke/yliner. Atmospheri pressure enters the flot owl hmer through the owl vents. This pressure fores fuel towr the low pressure re ehin the throttle vlve. Fuel flows through the min fuel jet into the min fuel well, up the ile tue, through the pilot jet, pst the off-ile pssges, pst the ile mixture jet (not shown), into the ile pssge, n into the ruretor throt. Air enters the ile iruit through the off-ile ports, efore the ir/fuel mixture is ishrge into the engine. Pge 3B R02 SEPTEMBER 2002

7 Off-Ile Ciruit CARBURETOR e l k j Ä g f i h - Air Blee Inlet - Flot Bowl Vent Inlet - Ile Air Blee Restritor - Off-Ile Dishrge Port e - Ile Dishrge Port f - Throttle Vlve g- Inlet Filter h- Bowl Drin i - Min Jet j - Pilot Jet k - Choke Vlve l - Air Flow As the throttle vlve rottes pst the off-ile ports, the ports re expose to the low pressure re ehin the throttle vlve. Aitionl fuel flows through the off-ile pssge, through the rer port, n s the throttle vlve ontinues to rotte, through the forwr ports. NOTE: The ile iruit will ontinue to supply fuel into the engine R02 SEPTEMBER 2002 Pge 3B-7

8 High Spee Ciruit i h f e g - Air Blee Inlet - Flot Bowl Vent Inlet - Ile Air Blee Restritor - Throttle Vlve e - Inlet Filter f - Min Dishrge Nozzle g- Min Jet h- Pilot Jet i - Air Flow As the throttle vlve rottes pst the off-ile ports, the low pressure re extens to the min ishrge nozzle. In ition, the inrese ir flow through the ruretor ore retes low pressure re insie the venturi. These omine fores rete strong sution over the min ishrge tue. Fuel flows through the min jet into the min fuel well, up the min ishrge nozzle, into the venturi. Air is mixe with the fuel to mke it lighter, ir enters the min fuel well through the min ishrge ir inlet tue. Cross holes (ir lees) re rille in the min ishrge tue, llowing the ir to mix with the fuel insie the min well. As the throttle vlve ontinues to open, itionl fuel is rwn out of the min ishrge tue, exposing itionl ross holes. At full throttle, the fuel mixture is ontrolle y the size of the min fuel jet. NOTE: Both the ile n off-ile iruits will ontinue to supply fuel into the engine. Pge 3B R02 SEPTEMBER 2002

9 Aelertion Ciruit CARBURETOR e ÄÄ f g i h - Air Flow - Aelertor Pump Dishrge Jet - Dishrge Pssge Outlet Chek Vlve - Plunger e - Dishrge Inlet Chek Vlve f - Diphrgm g- Return Spring h- Drin i - Inlet Pssge Chek Vlve During quik elertion when the throttle is open rpily, the ir flow n vuum hnge lmost instntneously, while the hevier fuel tens to lg ehin using momentry lenness. The elertor pump is use to provie the fuel neessry for smooth opertion uring this time. Fuel for elertion is supplie y spring loe iphrgm operte y pump shft n lever ssemly. The spring provies two funtions, one to return the iphrgm to the relxe position, n the seon to provie smooth sustine hrge of fuel. When the pump plunger moves upwr s hppens uring throttle losing, fuel enters the pump vities through the inlet hek vlves n fills the pump well. When the throttle vlve is opene, the onneting linkge fores the pump plunger ownwr in the fuel well. The ownwr motion of the plunger loses the inlet hek vlves, fores fuel into the pump ishrge pssge n opens the outlet hek vlve. Fuel then psses on through the hek vlve to the pump jet where it sprys into the venturi re. After the pump ishrge, the ishrge pssge outlet hek vlve loses, preventing itionl fuel flow R02 SEPTEMBER 2002 Pge 3B-9

10 Choke iruit e - Choke Vlve - Air Flow - Min Dishrge Tue - Off-Ile Dishrge Ports e - Ile Dishrge Port The hoke system onsists of hoke vlve, etent n push/pull le or eletri solenoi. The hoke opertion is ontrolle y the opertor to etermine engine requirement n orretly position the hnle on the le or tivte the eletri solenoi. When the engine is ol, the opertor pulls the le or tivtes the solenoi to lose the hoke vlve. As the engine is strte, low pressure re evelops insie the ruretor venturi. Atmospheri pressure flows through the opening in the hoke vlve into the low pressure re. Fuel is rwn into the ir strem through the min ishrge nozzle, off-ile ishrge ports, n ile ishrge ports. As the engine wrms up the opertor n reposition the hoke vlve or solenoi s esire. After the engine rehes operting temperture, the vlve is returne to the fully open position. Pge 3B R02 SEPTEMBER 2002

11 Cruretor Ajustments CARBURETOR 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 7 mm (0.28 in.) eyon rrel. Over-tightening srew my mge throttle linkge. - Throttle Linkge - 7 mm (0.28 in.) Length - Srew R02 SEPTEMBER 2002 Pge 3B-11

12 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 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 Pge 3B R02 SEPTEMBER 2002

13 4. Move throttle linkge forwr until linkge omes to rest on the pulley oss. CARBURETOR - 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 2.54 mm (0.1 in.). - Throttle Stop - Throttle Arm - Approximtely 2.54 mm (0.1 in.) Gp R02 SEPTEMBER 2002 Pge 3B-13

14 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 Pge 3B R02 SEPTEMBER 2002

15 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 Aelertor Ajustment 1. Ajust elertor rm lerne to mm (0.010 in.) mm (0.010 in.) - Bll - Three Bll Soket - Shutter Lever R02 SEPTEMBER 2002 Pge 3B-15

16 Cruretor Removl 1. Remove throttle linkge from ruretor rrel. - 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 Pge 3B R02 SEPTEMBER 2002

17 5. Remove olts. 6. Seprte intke/ruretor ssemly from powerhe. CARBURETOR - Bolts M8x40 (4) - Dowel Pin (2) - Gsket-Mnifol (isr) 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 R02 SEPTEMBER 2002 Pge 3B-17

18 Cruretor Disssemly 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 M4x12 (4) - Flot Bowl e - Vlve f - Gsket-Flot Bowl g- Srew M4x10 (2) h- Cover i - Gsket Pge 3B R02 SEPTEMBER 2002

19 4. Remove flot ssemly. CARBURETOR - Srew-M4x5 - Pin - Neele Vlve - Flot Assemly 5. Remove jets n nozzle. f g e - Min Nozzle - O-Ring - Min Jet - Pilot Jet e - Sel Cp f - Plte g- Srew-M3x R02 SEPTEMBER 2002 Pge 3B-19

20 6. Remove iphrgm n filter. g h j k f i e - Filter - Srew-M4x5 - Gsket-Drin Srew - Srews M4x8 (3) e - Bse f - Spring g- Ring h- Cp i - Diphrgm j - Plunger k - O-Rings (2) Pge 3B R02 SEPTEMBER 2002

21 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 R02 SEPTEMBER 2002 Pge 3B-21

22 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 M4x8 (3) i - Gsket-Drin Srew j - Srew M4x5 k - Filter Pge 3B R02 SEPTEMBER 2002

23 2. Instll jets n nozzle. CARBURETOR e f g - Plte - Srew M3x5 - Pilot Jet - Sel Cp e - Min Nozzle f - O-Ring g- Min Jet 3. Instll neele vlve onto flot hinge. - Flot - Neele Vlve - Pin R02 SEPTEMBER 2002 Pge 3B-23

24 4. Instll flot ssemly. - Flot - Pin M4x5 - Srew Flot Height Mesurement 1. Mesure flot height s shown, if out of speifition reple. P/N Cruretor Flot Height 15.5 ± 1.0 mm (0.61 ± 0.04 in.) or 36/64 in. - 41/64 in. Pge 3B R02 SEPTEMBER 2002

25 2. Instll rin srew, flot owl n over. CARBURETOR e h i f g - Gsket - Cover - Srew M4x10 (2) - Vlve e - Gsket-Flot Bowl f - Flot Bowl g- Srews M4x12 (4) h- Gsket-Drin Srew i - Drin Srew-M5x R02 SEPTEMBER 2002 Pge 3B-25

26 Cruretor Instlltion Eletri Choke Moels Instlltion 1. Assemle solenoi omponents s shown. f e - Coupling - Grommet - O-Ring - Hook - Solenoi e - Brket f - Solenoi Mounting Srew M5x8 (2) Solenoi Mounting Srew Torque 3.4 Nm (30 l-in.) 2. Instll solenoi to ruretor ssemly. Push grommet over pin n seure spring to ruretor with O-ring Solenoi Assemly - Grommet - O-Ring Pge 3B R02 SEPTEMBER 2002

27 3. Instll solenoi rket to powerhe with srews M6x16 (2). Connet BLUE to YELLOW/BLACK n BLACK le to BLACK le from remote ontrol. - Srew M6x16 (2) - Solenoi Brket Solenoi Mounting Brket Srew Torque 8 Nm (71 l-in.) R02 SEPTEMBER 2002 Pge 3B-27

28 4. Assemle intke/mnifol omponents to ruretor ssemly. 5. Seure ir intke with srews h e i g f - Mnifol - Gsket (2) (new) - Insultor - Cruretor Assemly e - O-Ring (New) f - Plte g- Spers h- Air Intke i - Srew M6x 100 (2) Cruretor Mounting Srew Torque 10 Nm (89 l-in.) Pge 3B R02 SEPTEMBER 2002

29 6. Instll intke/ruretor ssemly onto powerhe. CARBURETOR - Gsket-Mnifol (new) - Dowel pin (2) - Intke/Cruretor Assemly - Srew M6x40 (4) Mnifol Mounting Srew Torque 8 Nm (71 l-in.) 7. Instll j-lips. 8. Connet rether hose to ir intke n route hose through j-lips. - J-lips (2) - Brether hose R02 SEPTEMBER 2002 Pge 3B-29