Tle of Contents FUEL SYSTEM Section 3B - Cruretors CARBURETORS Attenutor And Cr Throttle Levers....... 3B-2 Fuel Lines.............................. 3B-4 Cruretor............................. 3B-6 Fuel System - Trouleshooting............ 3B-10 Generl Informtion.................. 3B-10 Reed Vlve Lek Test.................... 3B-12 Therml Air Vlve Circuit Description...... 3B-13 Enrichener System Description............ 3B-14 Mnul Opertion of Enrichener Vlve.. 3B-14 Enrichener Vlve Test................. 3B-15 Cruretor............................. 3B-16 Cruretor Fuel Circuits.................. 3B-17 Flot Bowl Circuit..................... 3B-17 Idle Circuit........................... 3B-18 Cold Strt Circuit..................... 3B-19 Off-Idle Circuit....................... 3B-19 Min Circuit.......................... 3B-20 Bck Drft Circuit..................... 3B-21 Cruretor Specifictions.............. 3B-22 Cruretor Plcement nd Jet Loction for Ech Cylinder........................ 3B-23 Cruretor Jet Plcement............. 3B-24 High Altitude Recommendtions........ 3B-25 Jet Prt Numer Chrt................ 3B-25 High Altitude Jet Chrt................ 3B-26 Removing Cruretor(s) from Engine...... 3B-27 Throttle Shft Screws................. 3B-28 Flot Adjustment..................... 3B-28 Instlling Cruretor(s) to Engine....... 3B-29 3 B 90-878079 JANUARY 2000 Pge 3B-1
Attenutor And Cr Throttle Levers Pge 3B-2 90-878079 JANUARY 2000
TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 1 1 SOUND ATTENUATOR PLATE 2 3 GASKET 3 6 SCREW (1/4-28 x 2-1/2) 60 7.0 4 6 WASHER 5 3 CAP PLUG 6 1 THROTTLE LEVER KIT 7 1 THROTTLE LEVER 8 1 THROTTLE LEVER 9 1 THROTTLE LINK 10 1 ROLLER 11 3 SCREW (10-32 x 3/4) 12 3 WASHER 13 3 LOCKWASHER 1 DECAL-EPA INFO (2000)(135)(SEE NOTE) 14 1 DECAL-EPA INFO (2000)(150/XR6/MAG. III/200) (SEE NOTE) 15 1 DECAL Cution Air Box NOTE: THE EPA LABEL HAS IMPORTANT INFORMATION ON EPA EMISSION REGULATIONS. REPLACE ANY MISSING OR UNREADABLE EPA LABEL. 90-878079 JANUARY 2000 Pge 3B-3
Fuel Lines A B C D A= to top cr.. B = to middle cr... C = to oil pump. D= to Cyl. Hed Pge 3B-4 90-878079 JANUARY 2000
Fuel Lines TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 1 1 FUEL LINE (4-1/2 IN.) 2 AR STA-STRAP 3 1 TEE 4 1 HOSE 5 1 CHECK VALVE 6 1 FUEL LINE (2 IN.) 7 1 HOSE 8 1 FUEL FILTER 9 1 HOSE (11 IN.) 10 2 FUEL LINE (4-1/2 IN.) 11 3 GASKET 12 6 STUD 13 6 LOCKWASHER 14 6 NUT 15 6 SCREW (1/4-20 x 7/8) 16 1 FUEL LINE (9 IN.) 17 2 HOSE (4-1/4 IN.) 18 1 HOSE (26 IN.) 19 1 ENRICHNER VALVE 20 1 CLAMP 21 1 SCREW (1/4-20 x 1/2) 22 1 FUEL LINE (4-1/2 IN.) 23 1 HOSE (3-3/4 IN.) 24 1 TUBING (18 IN.) 25 1 INLINE CONNECTOR 90-878079 JANUARY 2000 Pge 3B-5
Cruretor Pge 3B-6 90-878079 JANUARY 2000
Cruretor TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 1 TOP CARBURETOR 1 CENTER CARBURETOR 135 - WMV-15 1 BOTTOM CARBURETOR 1 TOP CARBURETOR 1 1 CENTER CARBURETOR 150/XR6/MAGNUM III 1 BOTTOM CARBURETOR WMV-16 1 TOP CARBURETOR 1 CENTER CARBURETOR 200 - WMV-18 1 BOTTOM CARBURETOR 2 6 COVER 3 6 GASKET 4 12 SCREW 18 2.0 5 3 GASKET 2 JET idle ir vent (.040-Top/Center)(135) 14 1.5 1 JET idle ir vent (.048 - Bottom)(135) 14 1.5 2 JET idle ir vent (.044-Top/Center)(150/XR6/Mgnum III) 14 1.5 6 1 JET idle ir vent (.048-Bottom)(150/XR6/Mgnum III) 14 1.5 1 JET idle ir vent (.038-Top)(200) PORT 14 1.5 1 JET idle ir vent (.028-Center)(200) 14 1.5 1 JET idle ir vent (.032-Bottom)(200) 14 1.5 90-878079 JANUARY 2000 Pge 3B-7
Cruretor Pge 3B-8 90-878079 JANUARY 2000
Cruretor TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 3 JET owl vent (.086)(135/200) 7 3 JET owl vent (.082)(150/XR6/Mgnum III) 1 JET idle ir vent (.036-Top)(135) 1 JET idle ir vent (.030-Center)(135) 1 JET idle ir vent (.038-Bottom)(135) STARBOARD 8 3 JET idle ir vent (.044)(150/XR6/Mgnum III) 1 JET idle ir vent (.038-Top)(200) 2 JET idle ir vent (.028-Center/Bottom)(200) 9 6 LIMITER CAP 10 6 IDLE MIXTURE SCREW/SPRING 11 3 LEVER KIT 12 3 SPACER 13 3 SPRING 14 3 GASKET fuel owl 15 3 FLOAT 16 3 FLOAT SHAFT 17 3 SCREW flot 10 1.0 18 3 VALVE SEAT KIT 19 3 GASKET vlve set 1 FUEL BOWL (TOP) 20 2 FUEL BOWL (CENTER/BOTTOM) 21 18 SCREW fuel owl 26 3.0 22 6 PLUG KIT 33 3.5 23 2 GASKET (Consists of 4 gskets) 6 JET min fuel (.072)(135) 14 1.5 6 JET min fuel(.074)(150/xr6/mgnum III) 14 1.5 24 1 JET-min fuel (.078)(200-Bottom-Port) 14 1.5 1 JET-min fuel (.084)(200-Bottom-Std) 14 1.5 25 2 TEE FITTING (TOP/CENTER) 26 1 ELBOW (BOTTOM) 2 JET min fuel (.080)(200-Top-Std/Center-Port) 14 1.5 2 JET min fuel (.082)(200-Top-Port)/Center-Std) 14 1.5 90-878079 JANUARY 2000 Pge 3B-9
Fuel System - Trouleshooting Generl Informtion Prolems, tht re thought to e cused y the fuel system, my e, in relity, something completely different. Items, tht re shown in the list on the left, could give the impression tht there is prolem in the fuel system. 1. Impeller 2. Sprk plugs 3. Ignition timing 4. Ignition sprk voltge 5. Cylinder compression 6. Reed vlves Prolem: Engine Turns Over But Will Not Strt Or Strts Hrd When Cold Possile Cuse Corrective Action Improper strting procedure used. Fuel tnk empty or too low. Improperly mixed fuel. Contminnts (wter, dirt, etc.) in fuel Fuel tnk ir vent closed or restricted. A pinched, cut or restricted fuel line. Also loose fuel line connection. Dirty or restricted fuel filter. Check proper strting procedure, s outlined in Opertion nd Mintennce Mnul. Check fuel in fuel tnk nd replce or dd whichever is necessry. Check ir vent on fuel tnk. Air vent must e open ll-the-wy nd free from ny contminnts. Check ll fuel lines nd replce s needed. Check nd tighten ll fuel line connections. Check nd replce or clen ll fuel filters. Low fuel pump pressure. Refer to Section 3A. An nti-siphon vlve. Refer to Checking for Restricted Fuel Flow in Section 3A. Choke solenoid, or enrichment vlve not operting. A needle nd set (in cruretor) tht is either stuck open or closed. Open=Flooding - Closed=Strving Improper cruretor jets, restricted jet or idle mixture screw out of djustment. Improper cruretor flot level. Check choke solenoid or vlve, nd electricl wiring to solenoid or vlve. Replce if necessry. Refer to Cruretor Disssemly in this section. Refer to Cruretor Adjustments in this section. Refer to Cruretor Adjustments in this section. Pge 3B-10 90-878079 JANUARY 2000
Prolem: Engine Idles Rough nd Stlls. Prolem: Engine Hesittes Upon Accelertion. Prolem: Engine Runs Uneven or Surges. Possile Cuse Improperly mixed fuel. Contminnts (wter, dirt, etc.) in fuel. Fuel tnk ir vent closed or restricted. A pinched, cut or restricted fuel line. Also loose fuel line connection. A dirty or restricted fuel filter. Low fuel pump pressure. Refer to Section 3A. Corrective Action CARBURETORS Check fuel in fuel tnk nd replce if necessry. Check ir vent on fuel tnk. Air vent must e open ll-the-wy nd free from restrictions. Check ll fuel lines nd replce s needed. Check nd tighten ll fuel line connections. Check nd replce or clen ll fuel filters. An nti-siphon vlve. Refer to Section 3A. A needle nd set (in cruretor) tht is either Refer to Cruretor Adjustments in this section. stuck open or closed. Open=Flooding - Closed=Strving Improper cruretor jets, restricted jet or idle mixture Refer to Cruretor Adjustments in this section. screw out of djustment. Improper cruretor flot level. Refer to Cruretor Adjustments in this section. Cruretor loose on reed lock housing. Tighten cruretor nuts securely. Reed lock housing loose, or gskets re defective. Improperly routed or restricted leed hose(s). REED VALVE SPECIFICATIONS Using pressure oil cn, spry 2-cycle oil round reed lock housing/crnkcse housing mtching surfces nd cruretor se. If engine RPM chnges, tighten or replce reed lock housing gskets or cruretor se gskets, s needed. Refer to leed line routing in this section. Reed Vlve Opening 1 -Mx. 0.020 in. (0.59 mm) 51851 90-878079 JANUARY 2000 Pge 3B-11
Reed Vlve Lek Test TOOLS REQUIRED FOR TEST:. Fuel Pressure Guge (0 to 15 psi)[0 103.4 kp]. Hose (pprox. 3 ft. x 1/8 in. ID)[274 cm x 3.2 mm ID] sme dimeter s leed hoses. 1. Remove engine cowling. 2. Plce outord in wter, strt nd llow to wrm up. NOTE: To gin ccess to cylinder #5 leed fitting remove throttle cm from throttle linkge. Refer to Cruretor Removl/lnstlltion for cm removl nd instlltion. 3. Remove nd plug leed hoses (one t time) from crnkcse cover nd connect fuel pressure guge s shown. 4. With engine t idle, reding of 3 6 psi (20.7 41.4 kp) must e ttined. If reding flls elow 3 psi (20.7 kp) inspect reed vlves. Refer to induction mnifold disssemly in Powerhed Section 4 of service mnul. Replce reed vlves or check vlves s required. NOTE: Check vlve is functioning if ir flows in one direction s shown. Pge 3B-12 90-878079 JANUARY 2000
Therml Air Vlve Circuit Description CARBURETORS -Therml Air Vlve 51863 The therml ir vlve circuit functions s n ir restrictor for the idle circuit which is controlled y therml open/close vlve monitoring engine temperture. The vlve is locted on the strord cylinder hed elow no. 3 sprk plug. When the engine temperture is elow 100 F (38 C) the therml ir vlve is closed. When cold engine is running, the therml ir vlve restricts ir to the idle circuit cusing the fuel mixture to e richer. When the engine wrms sufficiently, the therml vlve opens llowing required fuel/ir mixture for efficient opertion. 90-878079 JANUARY 2000 Pge 3B-13
Enrichener System Description -Mnul Primer Button -To Therml Air Vlve 51862 The enrichener system provides the engine with rich fuel chrge for strting ese of cold engine. The system consists of n electriclly operted enrichener vlve which is connected y hoses to the cruretors. Fuel is grvity fed to the vlve from the flot owl of the top cruretor vi hose. When the key (or choke utton) is pushed in (nd held in) current is sent to the vlve cusing it to open, which llows fuel to pss thru. The fuel psses thru hose nd is supplied to the engine vi fittings locted on top of the middle nd ottom cruretors. When the key (or choke utton) is relesed, the vlve will return to the closed position. The vlve cn e operted mnully if vlve fils to operte electriclly, refer to Mnul Opertion of Enrichener Vlve, following. Mnul Opertion of Enrichener Vlve IMPORTANT: Use of enrichener if engine is wrm could result in engine flooding. Squeeze primer ul until ul is firm. Press utton in on enrichener vlve nd hold pproximtely five seconds. Relese utton. Strt outord. Pge 3B-14 90-878079 JANUARY 2000
Enrichener Vlve Test CARBURETORS Push key (or choke utton) in. Vlve should click No Click Check for ttery voltge to yellow/lck wire t terminl lock on engine when key (or choke utton) is pushed in Click Squeeze primer ul until ul is firm. Remove hose from fitting on ottom of enrichener vlve. Plce continer under vlve, then push key (or choke utton). Check for fuel flow from fitting. Bttery Voltge Indicted Check for loose or corroded connection etween yellow/lck wire nd lck wire (under sme screw t terminl lock). Check tht other lck wire t terminl lock is properly grounded. Repir connection(s) s necessry, then push key (or choke utton) in. If enrichment vlve DOES NOT click, replce vlve. No Voltge Indicted Check for open in yellow/lck wire etween key switch (or choke utton) nd terminl lock. Fuel Flow from Fitting Vlve is O.K. Check hoses nd fittings from vlve to middle nd ottom cruretors for leds or ostructions. No Fuel Flow from Fitting Remove hose from top cruretor t vlve. If fuel flows from hose, replce vlve. If not, check hose nd fitting for leks or ostructions. ENRICHENER VALVE REPLACEMENT 1. Disconnect enrichener vlve leds t terminl lock. 2. Disconnect hoses from vlve. 3. Remove olt tht secures vlve mounting rcket to engine, then lift vlve from engine. 4. Reinstll hoses to vlve. 5. Apply drop of Loctite 271 (92-809820) to threds of mounting rcket retining olt, then secure vlve to engine with rcket nd olt. 6. Ground lck (vlve) led y inserting terminl lock retining screw thru led end nd terminl lock, nd then securing to engine using screw. 7. Connect yellow/lck led (from engine hrness) to yellow/lck vlve led y inserting screw thru led ends, nd securing to terminl lock using screw. 90-878079 JANUARY 2000 Pge 3B-15
Cruretor 54350 1 -Enrichener Hose Fitting 2 -Cruretor Numer 3 -Fuel Mixture Adjustment Screw 4 -Bck Drft Vent Jet 5 -Idle Air Bleed Jet 6 -High Speed Fuel Jet Access Plug (2) 7 -Fuel Line Fitting 8 -Min Nozzle Well Vent (2) Pge 3B-16 90-878079 JANUARY 2000
Cruretor Fuel Circuits CARBURETORS Flot Bowl Circuit c Key Air Fuel i j g d h -To Engine Crnkcse -Throttle Plte c -Cruretor Venturi d-flot e -Flot Bowl f -Min Fuel Well g-min Jet h-fuel from Fuel Pump i -Inlet Set j -Inlet Needle f e Fuel from the fuel pump enters the cruretor through the fuel inlet fitting nd fills the owl until the flot moves the inlet needle ginst the fuel inlet set. With the inlet needle ginst the inlet set, the fuel inside the flot owl is t it s mximum level. Fuel inside the owl flows through the min fuel jet nd fills the min fuel well. 90-878079 JANUARY 2000 Pge 3B-17
Idle Circuit c n m l k f d Key e Air Fuel j -Idle Pssge -Idle Mixture Screw c -Bck Drft Jet d-idle Air Jet e -Therml Air Vlve (open) f -Air Flow g-flot Bowl h-idle Tue i -Min Fuel Jet j -Min Fuel Well k -Secondry Idle Air Bleed l -Throttle Plte m-off-idle Ports n-off-idle Pssge h i g As the engine rottes, the piston moves wy from the crnkcse. This movement cretes low pressure re ehind the throttle plte. Atmospheric pressure pushes ir through the cruretor throt (venturi), pst the throttle plte (smll hole in plte) nd into the low pressure re inside the crnkcse. Atmospheric pressure enters the flot owl chmer through the ck drft jet. This pressure forces fuel towrd the low pressure re ehind the throttle plte. Fuel flows:. Through the min fuel jet into the min fuel well, (1.) Up the idle tue, (2.) Through the off-idle pssges, (3.) Pst the idle mixture screw, (4.) Into the idle pssge (5.) And into the cruretor throt. Air enters the idle circuit through the idle ir jet nd secondry idle ir leed. This ir mixes with the fuel inside the idle pssge efore the ir/fuel mixture is dischrged into the engine. Rotting the idle mixture screw will chnge the ir/fuel mixture t idle speeds. Pge 3B-18 90-878079 JANUARY 2000
Cold Strt Circuit CARBURETORS Key Air Fuel Off-Idle Circuit -Therml Air Vlve (closed) -Air Flow A cold engine will require richer mixture. Fuel is supplied to the cruretors y the solenoid operted enrichner vlve. d c f e Key Air Fuel -Off-Idle Ports -Off-Idle Pssge c -Idle Air Jet d-from Open Therml Air Vlve e -Air Flow f -Throttle Plte 90-878079 JANUARY 2000 Pge 3B-19
Min Circuit As the throttle pltes rotte pst the off-idle ports, the ports re exposed to the low pressure re ehind the throttle plte. Additionl fuel flows through the off-idle pssge; through the rer port; nd s the throttle plte continues to rotte, through the forwrd port. c i h d Key Air Fuel g e -From Open Therml Air Vlve -Air Flow c -Venturi d-min Dischrge Air Inlet Tue e -Cross Holes f -Min Fuel Well g-min Fuel Jet h-min Dischrge Nozzle i -Throttle Plte f As the throttle plte rottes pst the off-idle ports, the low pressure re extends to the min dischrge nozzle. In ddition, the incresed ir flow through the cruretor ore cretes low pressure re inside the venturi. These comined forces crete strong suction over the min dischrge tue. Fuel flows: 1. Through the min fuel jet into the min fuel well, 2. Up the min dischrge nozzle, 3. Into the venturi. Air is mixed with the fuel to mke it lighter, ir enters the min fuel well through the min dischrge ir inlet tue. Cross holes re drilled in the min dischrge tue, llowing the ir to mix with the fuel inside the min well. As the throttle plte continues to open, dditionl fuel is drwn out of the min dischrge tue, exposing dditionl cross holes. At full throttle, the fuel mixture is controlled y the size of the min fuel jet. Pge 3B-20 90-878079 JANUARY 2000
Bck Drft Circuit CARBURETORS g f d c Key Air Fuel e NOTE: Fuel Flow Not Shown For Clrity -Bck Drft Port -Bck Drft Jet c -Air Flow d-min Dischrge Tue e -Fuel Bowl f -Fuel Bowl Vent Pssge g-throttle Plte At prtil throttle settings, the ck drft circuit lens out the mixture for incresed fuel economy. The ck drft circuit uses the flot owl vent circuit nd owl vent jet to len out the ir/fuel mixture. The owl vent jet limits the mount of ir entering the flot owl vent circuit. With the throttle plte positioned correctly, the low pressure re is exposed to the ck drft port inside the cruretor ore. The flot owl vent circuit is connected y pssges to the ck drft port. The low pressure re pulls ir out of the owl vent circuit. Due to the size of the vent jet nd the ir loss through the ck drft port, the ir pressure on the fuel inside the fuel owl is lowered to elow tmospheric pressure. Lower pressure on the fuel inside the flot owl, lowers the mount of fuel eing forced out of the min dischrge tue. 90-878079 JANUARY 2000 Pge 3B-21
Cruretor Specifictions SYNCHRONIZING CARBURETORS IDLE MIXTURE SCREW To synchronize cruretors, refer to Timing/Synchronizing/Adjusting section. For est running qulity, the djustle idle mixture screws re set t the fctory with the limit ts pointing stright up (pprox. 1-1/2 turns out for Model 135) (1-1/4 turns out for Models 150 nd 200). If djustment is required, ll idle mixture screws must e turned the sme mount nd the sme direction. Turning the idle mixture screws (recommended 1/8 turn t time) clockwise will len the idle mixture. Turning the idle mixture screws counterclockwise will richen the idle mixture. FLOAT LEVEL ADJUSTMENT There is one flot nd one flot owl for 2 cylinders. To set flot height, invert flot owl nd djust flot tng until top of flot is even with top of flot owl. JET LOCATION FOR EACH CYLINDER Cruretor jets nd djustment screw instlled in the strord side of the cruretor supply fuel to the port cylinder, jets nd djustment screw instlled in the port side supply fuel to the strord cylinder. NOTE: The idle jet nd ck drft jet ffect oth cylinders. Pge 3B-22 90-878079 JANUARY 2000
Cruretor Plcement nd Jet Loction for Ech Cylinder CARBURETORS TOP WMV 15-1 Cylinder #2 A Cylinder #1 MIDDLE WMV 15-2 Cylinder #4 A Cylinder #3 BOTTOM WMV 15-3 Cylinder #6 A Cylinder #5 A Bckdrft Jet Affects Both Cylinders 54349 NOTE: Cruretor jets nd djustment screw instlled in the strord side of the cruretor supply fuel to the port cylinder, jets nd djustment screw instlled in the port side supply fuel to the strord cylinder. 90-878079 JANUARY 2000 Pge 3B-23
Cruretor Jet Plcement NOTE: Jets listed re for engine opertion from 0 5000 feet (0 1524m) of elevtion. Model 135 WMV 15-1 WMV 15-2 WMV 15-3 PORT Bore STBD Bore PORT Bore STBD Bore PORT Bore STBD Bore Min Jet.072.072.072.072.072.072 Idle Air Bleed Jet.040.036.040.030.048.038 NOTE: Jets listed re for engine opertion from 0 5000 feet (0 1524m) of elevtion. Model 150 WMV 16-1 WMV 16-2 WMV 16-3 PORT Bore STBD Bore PORT Bore STBD Bore PORT Bore STBD Bore Min Jet.074.074.074.074.074.074 Idle Air Bleed Jet.044.044.044.044.048.044 NOTE: Jets listed re for engine opertion from 0 5000 feet (0 1524m) of elevtion. Model 200 WMV 18-1 WMV 18-2 WMV 18-3 PORT Bore STBD Bore PORT Bore STBD Bore PORT Bore STBD Bore Min Jet.082.080.080.082.078.084 Idle Air Bleed Jet.038.042.028.028.028.028 Bck Drft Vent Jet c.086.086.086 Bck Drft Vent Jet c.082.082.082 Bck Drft Vent Jet c.086.086.086 c PORT CYL. BORE CYLINDERS 2,4,6 (STBD. SIDE of ENGINE) STBD. CYL. BORE CYLINDERS 1,3,5 (PORT SIDE of ENGINE) Pge 3B-24 90-878079 JANUARY 2000
High Altitude Recommendtions NOTE: Refer to Jet Chrts for jet sizes nd prt numers. CARBURETORS IMPORTANT: When operting outord ove 5000 ft. (1524m), it is recommended outord ger rtio e reduced s shown in chrt elow: Model High Altitude Ger Rtio Chnge 135/150 with 2:1 Rtio 2.3:1 High Altitude Ger Kit 150 Mg III/XR6 with 1.78:1 Rtio 2:1 Complete Gercse 150 Mg III,XR6,200 with 1.87:1 Rtio 2:1 Rtio Ger Set or Complete Gercse Jet Prt Numer Chrt Jet Orifice Size (inch) JET ORIFICE SIZE/PART NUMBER CHART 10-32 Jet Jet Jet Orifice Orifice Orifice Prt Numer Size Prt Numer Size Prt Numer Size Prt Numer (inch) (inch) (inch).040 19266040.058 1395-7831.076 1399-3796.094 1395-8423.042 1399-5315.060 1395-6487.078 1395-6680.096 1399-6249.044 1395-7394.062 1399-4217.080 1395-6201.098 1395-7355.046 1399-5317.064 1399-4216.082 1399-3518.048 1395-6246.066 1399-4215.084 1399-3517.050 1395-6028.068 1395-6029.086 1395-5815.052 1395-6359.070 1395-6030.088 1395-6202.054 1399-5225.072 1395-6207.090 1395-6247.056 1399-5213.074 1399-3794.092 1395-5733 Jet Orifice Size (inch) JET ORIFICE SIZE/PART NUMBER CHART 8-32 Jet Jet Jet Orifice Orifice Orifice Prt Numer Size Prt Numer Size Prt Numer Size Prt Numer (inch) (inch) (inch).030 810741.038 815633038.046 815633046.054 815633054.032 1399-3252.040 1399-7570.048 815633048.070 815633070.034 1395-3251.042 815633042.050 815633050.076 815633076.036 1399-3026.044 810742.052 815633052 NOTE: Thred size for V-6 model cruretor min, idle ir nd ck drft jets re 10-32 NOTE: Thred size for V-6 model cruretor progression jets re 8-32 90-878079 JANUARY 2000 Pge 3B-25
High Altitude Jet Chrt Fctory instlled min fuel jets re normlly dequte for proper performnce up to pproximtely 5000 feet (1524m) ove se level. Between 2000 feet (609.6m) nd 5000 feet (1524m) the reduction of the min fuel jet(s) my result in improved performnce nd fuel economy. Aove 5000 feet, however, it is recommended tht min jet size e reduced s shown per 1000 feet (304.8m) in the following chrt. Feet Meter 1000 304.8 2000 609.6 3000 914.4 4000 1219.2 5000 1524 6000 1828.8 7000 2133.6 8000 2438.4 9000 2743.2 10000 3048 110003 352.8 12000 3657.6 Jet Size 0.034 0.034 0.034 0.032 0.032 0.032 0.032 0.032 0.032 0.030 0.030 0.030 0.030 0.036 0.036 0.036 0.034 0.034 0.034 0.034 0.034 0.032 0.032 0.032 0.032 0.032 0.038 0.038 0.038 0.036 0.036 0.036 0.036 0.036 0.034 0.034 0.034 0.034 0.034 0.040 0.040 0.040 0.038 0.038 0.038 0.038 0.038 0.036 0.036 0.036 0.036 0.034 0.042 0.042 0.042 0.040 0.040 0.040 0.040 0.038 0.038 0.038 0.038 0.038 0.036 0.044 0.044 0.044 0.042 0.042 0.042 0.042 0.040 0.040 0.040 0.040 0.038 0.038 0.046 0.046 0.046 0.044 0.044 0.044 0.044 0.042 0.042 0.042 0.042 0.040 0.040 0.048 0.048 0.048 0.046 0.046 0.046 0.046 0.044 0.044 0.044 0.042 0.042 0.042 0.050 0.050 0.050 0.048 0.048 0.048 0.046 0.046 0.046 0.046 0.044 0.044 0.044 0.052 0.052 0.050 0.050 0.050 0.050 0.048 0.048 0.048 0.048 0.046 0.046 0.046 0.054 0.054 0.052 0.052 0.052 0.052 0.050 0.050 0.050 0.048 0.048 0.048 0.048 0.056 0.056 0.054 0.054 0.054 0.054 0.052 0.052 0.052 0.050 0.050 0.050 0.048 0.058 0.058 0.056 0.056 0.056 0.056 0.054 0.054 0.054 0.052 0.052 0.052 0.050 0.060 0.060 0.058 0.058 0.058 0.056 0.056 0.056 0.054 0.054 0.054 0.052 0.052 0.062 0.062 0.060 0.060 0.060 0.058 0.058 0.058 0.056 0.056 0.056 0.054 0.054 0.064 0.064 0.062 0.062 0.062 0.060 0.060 0.060 0.058 0.058 0.058 0.056 0.056 0.066 0.066 0.064 0.064 0.064 0.062 0.062 0.062 0.060 0.060 0.060 0.058 0.058 0.068 0.068 0.066 0.066 0.066 0.064 0.064 0.064 0.062 0.062 0.060 0.060 0.060 0.070 0.070 0.068 0.068 0.068 0.066 0.066 0.064 0.064 0.064 0.062 0.062 0.062 0.072 0.072 0.070 0.070 0.070 0.068 0.068 0.066 0.066 0.066 0.064 0.064 0.062 0.074 0.074 0.072 0.072 0.070 0.070 0.070 0.068 0.068 0.068 0.066 0.066 0.064 0.076 0.076 0.074 0.074 0.072 0.072 0.072 0.070 0.070 0.068 0.068 0.068 0.066 0.078 0.078 0.076 0.076 0.074 0.074 0.074 0.072 0.072 0.070 0.070 0.068 0.068 0.080 0.080 0.078 0.078 0.076 0.076 0.076 0.074 0.074 0.072 0.072 0.070 0.070 0.082 0.082 0.080 0.080 0.078 0.078 0.076 0.076 0.076 0.074 0.074 0.072 0.072 0.084 0.084 0.082 0.082 0.080 0.080 0.078 0.078 0.076 0.076 0.076 0.074 0.074 0.086 0.086 0.084 0.084 0.082 0.082 0.080 0.080 0.078 0.078 0.076 0.076 0.074 0.088 0.088 0.086 0.086 0.084 0.084 0.082 0.082 0.080 0.080 0.078 0.078 0.076 0.090 0.090 0.088 0.088 0.086 0.086 0.084 0.084 0.082 0.082 0.080 0.080 0.078 0.092 0.092 0.090 0.090 0.088 0.088 0.086 0.086 0.084 0.084 0.082 0.082 0.080 0.094 0.094 0.092 0.092 0.090 0.090 0.088 0.088 0.086 0.086 0.084 0.084 0.082 0.096 0.096 0.094 0.094 0.092 0.092 0.090 0.090 0.088 0.086 0.086 0.084 0.084 0.098 0.098 0.096 0.096 0.094 0.092 0.092 0.090 0.090 0.088 0.088 0.086 0.086 Pge 3B-26 90-878079 JANUARY 2000
Removing Cruretor(s) from Engine CARBURETORS 1. Remove top cowling. IMPORTANT: Plce n identifying mrk on ech cruretor efore removl s ech cruretor must e reinstlled in sme loction from which removed. NOTE: As ech cruretor is removed from intke mnifold, their respective fuel enrichment hose should e disconnected. 2. Remove ir ox cover nd het shield from engine. 3. Remove throttle linkge from throttle levers s shown. 4. Remove oil pump link rod from throttle lever. -Throttle Linkge -Oil Pump Link Rod 51706 5. Remove fuel hose nd fuel enrichment vlve hose from cruretors. -Fuel Hose -Enrichment Vlve Hoses 55003 6. Cruretors my now e removed individully. Mrk loction of ech cruretor nd reinstll in sme loction. Remove cruretor(s) secured y two nuts nd two llen hed type olts. 90-878079 JANUARY 2000 Pge 3B-27
Throttle Shft Screws NOTE: It is recommended tht the screws securing the throttle pltes to the throttle shft NOT BE REMOVED due to the difficulty in otining correct lignment of throttle pltes during ressemly. If screws must e removed, pply Loctite 271 to screw threds efore reinstlling screws. c -Throttle Shft -Throttle Shutter Plte c -Screws Flot Adjustment 51860 NOTE: Flot height djustment is the only djustment mde to djust flot setting. 1. Adjust flot height y turning fuel owl upside-down, then djust flot t until flot is level with edge of fuel owl. Adjust flot t if necessry. d c -Flot (Adjust y ending t) -Fuel Bowl (Upside-Down) c -Flot Level Even with Bowl Edge d-flot T 51713 Pge 3B-28 90-878079 JANUARY 2000
Instlling Cruretor(s) to Engine CARBURETORS 1. Plce new cruretor gskets onto cruretor mounting studs on intke mnifold. 2. Instll cruretors (in respective loctions) onto mounting studs nd secure in plce with nuts nd llen type olts. 3. Connect enrichment hoses nd fuel hoses. Secure hoses in plce using st-strps. -Fuel Hose -Enrichment Vlve Hose 55003 4. Attch throttle linkge nd oil pump link rod to cruretors s shown. -Throttle Linkge -Oil Pump Link Rod 51706 5. Re-synchronize cruretors following cruretor instlltion. Refer to Timing/Synchronizing/Adjusting Section 2C. IMPORTANT: Inspect ll fuel hose connections, nd cruretor flot owl split lines for fuel leks with engine running. Also inspect ech cruretor throt, with outord running t low RPM, for fuel driling out of vent tue which would e indictive of flot nd/or needle nd set ssemly not functioning properly. IMPORTANT: Engine should not e operted ove 3000 RPM with ir ox cover removed s engine will run too len nd internl dmge could result. 90-878079 JANUARY 2000 Pge 3B-29