FUEL SYSTEM & CARBURETION 3 A CARBURETOR R1 JUNE 1996 FUEL SYSTEM AND CARBURETION

Transcription

1 FUEL SYSTEM & CARBURETION 3 A CARBURETOR R1 JUNE 1996 FUEL SYSTEM AND CARBURETION 3A- 1

2 Tle Of Contents Pge Removing Cruretor A-1 Disssemling Cruretor A-1 Assemling Cruretor A-3 High Altitude Jetting A-5 Exploded View - Cruretor - 90/95/120 HP A-6 3A-0 FUEL SYSTEM AND CARBURETION R1 JUNE 1996

3 Removing Cruretor 1. Remove nut securing throttle cm to stud. Disssemling Cruretor 1. Remove idle mixture screw nd spring. - Nut, Throttle Cm 2. Remove throttle cm form stud. NOTE: Cruretors nd cover my e removed s n ssemly. 3. Remove E clips from throttle rm. - Screw, Idle Mixture - Spring 2. Remove screw, gsket, fuel owl, nd gsket. d c - E Clips 4. Remove throttle r ssemly. 5. Disconnect fuel line. 6. Remove primer hoses from cruretor. 7. Remove cruretor flnge nuts. 8. Remove cruretor(s). - Gsket - Fuel Bowl c - Gsket d - Screw 3. Remove fuel owl gsket from groove in cruretor. - Gsket R1 JUNE 1996 FUEL SYSTEM AND CARBURETION 3A-1

4 4. Remove flot. c Drive out flot pin. NOTE: Drive flot pin through so tht knurled end comes out first. e d - Flot - Pin, Knurled End Remove flot. 5. Remove inlet needle. - Screws nd Wshers - Shutter, Throttle c - E-Clip 7. Remove min fuel jet. d - Return Spring e - Throttle Shft - Min Fuel Jet 8. 90/95 HP - Remove idle ir jet. 120 HP - Remove seling screw nd intermedite fuel jet. c - Inlet Needle As Needed 6. Remove throttle ssemly. Remove screws nd wsher from shutter. Hold throttle in wide open position. Pull throttle shutter out of housing. Remove E-clip. Unhook return spring from drive pin on cruretor. 90/95 HP - Idle Air Jet - Intermedite Fuel Jet 120 HP c - Seling Screw Pull throttle shft out of housing. 3A-2 FUEL SYSTEM AND CARBURETION R1 JUNE 1996

5 9. Remove elow. NOTE: In some cses, the position of the idle tue my mke it necessry to remove the tue prior to removing the nozzle. - Elow 10. Remove welch plug. Drill hole through welch plug. IMPORTANT: Do not drill into cruretor ody. Insert smll screwdriver in hole nd pry plug out of housing. 13. Inspect the following: Inspect: Idle mixture screw Inlet needle Idle spring Primer connectors Body Jets Look For: Rings or grooves on point Rings or grooves on point Compressed spring Clogging Pitting Clogging 14. Clen entire cruretor with solvent. 11. Remove idle tue. Plce punch on ottom end of idle tue. IMPORTANT: Note the depth of the idle tue prior to removl. It must e instlled to this position. Crefully tp on punch until cup plug nd idle tue come free of ody chnnel. 12. Unscrew min nozzle nd remove it from ody chnnel. IMPORTANT: Do not llow non-metl prts to come in contct with solvent. WARNING Follow solvent mnufcturer s directions for use. Assemling Cruretor 1. Thred min nozzle into ody chnnel. IMPORTANT: Idle tue must contct nozzle in front or cruretor will run len. NOTE: Be sure nozzle is threded in completely. Do not over tighten nozzle. 2. Instll idle tue. Slide idle tue (flnged end up) into ody chnnel. IMPORTANT: Idle tue must contct nozzle in front or engine will run len. - Min Nozzle R1 JUNE 1996 FUEL SYSTEM AND CARBURETION 3A-3

6 Crefully tp cup plug into opening with punch. - Idle Tue - Cp Plug Sel plug with nil polish. 3. Plce welch plug into recess of cruretor ody. Crefully tp center of welch plug. NOTE: Tpping will spred the plug nd hold it in plce. 6. Instll throttle ssemly. Slide throttle shft into cruretor housing. Ly end of return spring on ledge of housing. Secure throttle shft with E-clip. Turn throttle shft rm clockwise until flt side of shft fces up. Slide shutter into slot of shft with numered side fcing out. Apply Loctite (Specil Tool No. FT ) to screws nd instll in throttle shutter. d c e f g - Welch Plug - Elow Sel top of plug with nil polish. 4. Instll elow. 5. Instll min fuel jet. h - Throttle Shft - Return Spring c - Housing Ledge d - E-Clip 7. Instll inlet needle. e - Throttle Shft Arm f - Throttle Shft with Flt Side Fcing Up g - Shutter h - Screws - Min Fuel Jet - Needle 3A-4 FUEL SYSTEM AND CARBURETION R1 JUNE 1996

7 8. Instll flot. Position flot on cruretor. Crefully slide pin through rcket nd flot. Tp pin until knurled end is retined in cruretor csting. 11. Instll fuel owl ssemly: owl, gskets, nd screw. High Altitude Jetting The cruretor jet is for engine opertion t se level through 2500 feet (762 m) ove se level. For engine opertion ove 2500 feet re-jet the cruretor to the size nd ltitude specified elow MAIN FUEL JET SIZE 90/95XR HP Sport Jet Cruretor Operting Elevtion Top Middle Bottom Se Level-2500 ft ft ft ,000 ft Flot - Pin 9. Mesure flot height. NOTE: To djust, end inlet needle t on flot until flot sits prllel to flnge. - Prllel to Flnge - Flot T 10. Instll gsket in groove t ottom of cruretor MAIN FUEL JET SIZE 120 HP Sport Jet Cruretor Operting Elevtion Top Bottom Se Level-1500 ft ft ft ft ,000 ft MAIN FUEL JET SIZE 120XR HP Sport Jet Cruretor Operting Elevtion Top Bottom Se Level-1500 ft ft ft ft ,000 ft Gsket R1 JUNE 1996 FUEL SYSTEM AND CARBURETION 3A-5

8 Exploded View - Cruretor - 90/95/120 HP 1 - Gsket 2 - Plug 3 - Plug 3 -Tue, Idle 4 - Elow 5 - E-Clip 6 - Cruretor 7 - Idle Jet 7 -Seling Screw 8 - Needle 10 - Pin 11 - Gsket 12 - Gsket 13 - Bowl 13 Bowl (Top Cr) 14 - Gsket 15 - Screw 16 - Flot 17 - Min Nozzle 18 - Min Jet 19 - Idle Mixture Screw 20 - Spring 21 - Screw 22 - Roller 23 - Nut 24 - Shft 25 - Spring 26 - Throttle Shutter 27 - Screw (2) B 120 HP Quicksilver Luriction/Selnt Appliction Points B Loctite 271 ( ) 3A-6 FUEL SYSTEM AND CARBURETION R1 JUNE 1996