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    PE Carburetor Troubleshooting Manual Compressed PDF

    Uploaded by

    Rigel Pacis

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 308
    PREFACE ‘This manual provides @ wide range of infrmation about Honda float Bow! carburetor Unless otherwise noted, th instusons are based on 12 series, but thoy hold tus for the majority ower Equipment earbureors Since 1995, Honda has produces engines that comply wih sir or both the California Ar Resources Board (CARE) anaior the Envrenmantal Protection Agency (EPA) regulatons. All engines produced since ‘August 31, 1895, are cote. ‘Ai efematon contained inthis manuals based onthe latest product information avaliable atthe time of Dring, We reserve the ight to make changes at any tine wthout noice. No par ofthis pubicaton may be reproduced, stored in relieval system, or anamitd,n any fm by any ‘means, electonic, mechanical, photocopying, cording, Crotherwise, without the por writen permission ofthe publisher. Ths includes text, hours, and tables ‘As you rea this manual, you wil fn information thats preceded by a NOTICE] symbol. The purpose ofthis ‘other property, or the envitonmont SAFETY MESSAGES ‘Your safety and the safety of others are very important To hap you make informed decisions, we have proviced safety massages and other safety infomation {teoughout this manual, Of couse ts not practical or possible to warn you about al he hazards assocated ti servicing these producs. You must use yout on 00d judgement ‘You wil find important safety information in a variety of forma, inducing 1 Satety Labels onthe product, + Safety Messages — preceded by a safsty alert symbol J. and one of thee signal words DANGER, WARNING, or CAUTION. These sal words mean You Wt be KILLED PTS seivctsch iter yu FROIN Serials Ht you Son low insctens FRONT Jo o28 svon + Instructions ~ how to service carburetors cotrecty ‘on satay. CONTENTS [intropuction Ea SERVICE INFORMATION Ea CARBURETOR SERVICE Ea TOOLS __ Ea HIGH ELEVATION oPeRaTiOn ES CHOKE SYSTEMS Ea MEMO INTRODUCTION INTRODUCTION Hae INTRODUCTION INTRODUCTION CARBURETOR All Honda Power Equipment engines (except metoing diaphragm, LPG-tusles, CODE ‘and isl models) have floal-Dow!-ypo carburetor, Curent there are eleven (eight most popular covered i ths manual) distin! carburetor code greups. The ‘code fs cat into the carburetor as shown in the istration ‘Tne code groups for in body shape, contol oration, and jet types, but they all share similar inspection and austen procedures. This manual is intended to be a general guido to Honda Power Equipment float oud type and metering laphragm carburetors. Refer to the eppropiste shop manus! for more speciic 'nformation about indvicual models. CARBURETOR CODE GROUPS LISTED BY ENGINE TYPE AND MODEL. Carbarator 1 Gale | none Tyee apa encne mods Aplcala poner rot) | 38 [ate SV Gc Vara) G08 6150, 620,900,400 | | + GV engine ‘GV100, GV150, GV200, Gv400, Ex800, EM/EXS00 | {Genwi Tar Sevieowen Pune, cawntiows oe) | | ‘aes eadsTORE Tecra, acts, G10, 65180, GOV195,Gov'60, OVI, (Graton am ann _| 85019 (Gaeto, Sorbioner, Pr, avn Mowe) aoe, iqua-oled OH (Qvernead Cam) ean BE | estore OFV (Overhead | GXITO TED, SETA, GKTRD, SRS, HEAD STO, HG, vate) Shown oar coian ontntar esr Bo OarsoS Tange Sats 5 Sevengne {Generar Te Seonlover, Pump Lawn Mower ‘cour ara Toco Rng Mowe Ln acs) “Fairoke, walersooled ORC ” - ‘ec, HS Geet Toy = SF —— retora 5 Si avy] GT00K, G00, GVIOOK, EGEORED, EDEN, EXTON, oem Fztoate Ht, Oxt00, OXHE0, VED, OVST {Gerure T Lown Nowe) BE Haake ak sede, | GHB, SXRD, GHVETO,GRVERE,GXETORT, EAT, Cian fOreesiabey | SxvetOe Gnezoe “4-siroke, liquid-cooled OHC a (Overmead Cam) eee _ BK ‘4-stroke, air cooled OHV, a 7] \Vetwin (Overhead Valve) one Bi | estore, a ced 6, | cova, on ~ Vin (Overhead Cam)" __| SOVS20. GXV530 ste a coed OV, GEESE [ono cre orien, ee, ovee0 FR | i -toke, OH (ve | 09 arma erie wih dapragm ype carat) Wis | Ministre, OHC Overhead | x05, x95 ier, Timmer, Water Pump) We [Bert seks OFT oat | ce Gr ner ser Pane) ‘SERVICE INFORMATION SERVICE INFORMATION ‘SERVICE RULES. FUEL LINE AND CLAMP CHANGES. FUEL RECOMMENDATIONS. FUEL SYSTEM PREVENTIVE MAINTENANCE STORAGE. EMISSION REGULATIONS PILOT SCREWILIMITER CAP REPLACEMENT. 22 son BS nD 28 26 2B 29 Ei SERVICE INFORMATION SERVICE RULES 4. Use Honda Genuine parts and lubricants or ther equivalents. Pars tht do net mest Hende's design spectieatons may damage the unit or result in emision voltions (ene page 2-8). Use the special tools designed forthe product. ‘Always intal now gaskets, O-ings, ot. when reasserbing “ighion al fastoners othe specified torque curing reassembly ‘Clean the outside ofthe carburetor before disassembly Clean desasombed pare wth Honda CarburetouCombuston Cleaner and then bow dy them wt low pressure compressed a Some commercially avatable chemical carburetor cleaners ara very caustic. These cleaners may ‘damage plastic pars such as O-rings, floats, and flat valve seals. Check the container for instructions. IF you are in doubt, do not use these products to clean Honda carburetors. Honda Carburetor Cleaners 100% fee af chlorinated solvents. This product removes gum, varnish and deposits from carbureter components. Honda Carburetor Cieaner is avalabe mn 18-ounce aerosol cans and & specaly formulated fr use in Calflora, Desapten Patter [tate au Cuneo CAne016 fe: 7. Aterrnesondy, check pats errope operon, andahare eck orint (cigs ser erat eer Sat Burs 2-2 ‘SERVICE INFORMATION FUEL LINE AND CLAMP CHANGES ‘Al Honda Power Equipment manufactured after January 1,2008 (and some manufactured afte 1/1108), uses low permeable ua lin. The low-permeable fv! ne is easy to spot. The fue ne has the EPA Executive Order (€-U-05.008) printed on tand requires “D sive hose clamps “This type of fuel ne is rquied to ensure proper emissions compliance. Substituting non-4ow-permeable ful ine s considered tampering (page 28). = ‘The low-permeable fuel ne has a coating onthe inside to koep fuel vapors ram escaping. The coating makes the Inside of he ful line sick. To ensure the fue ine stays in place, you must only use fe “O° style uel clamps. The old lreype clamps wil not old the low permeable fuel linen place, ‘Te oldtye fuel line and wire hose clamps are shown below. ae You may use "D” syle fuel clamps onthe oye fuel tne, but naver use wit fel ine clamps on low-permeable fue Ine. 2-3 SERVICE INFORMATION FUEL RECOMMENDATIONS Engin 5 carted to operate on rogiarunioaced gasoline wih a pump octane rating of 86 or higher. [Never use stale or contaminated gasoline or an oligasolne mire, Avold gating dt or water inthe fuel ark ‘You may use regular unleaded gasoline containing no mere than 10% ethanol (E10) or 5% methanol by volume, In ‘adction, methanol must contain cosovents and corrosion inhibitors Use of fels with @contant of ethancl or methanol greater than shown above may cause staring andlor performance probioms.Itmay also damage metal, rubber, and plastic pats ofthe fuel system Engine damage or performance problems that resut from using ful with percentages of ehano or methane! greater than shown above are not cxvered under warranty Ifthe equloment wil be used on an infrequent bass, please refer to STORAGE AND FUEL DETERIORATION (soo. ‘page 28) for adctona infrmation ragarcing fuel delaioaton and storage. Ethanol and Honda Engines Honda engines are designed and certfled to run on regular unleaded gasoline, Honda product owner's manuals speciy a maximum of 10% ethanol n gasoline for our products; other oxygenates ae aso listed. Honca engin aro {eslgned for good performance and efficient operation using gaslin containing frm Oto 10% etnano. ‘Some facts about ethanol + thanolis hygrescopi, which means it aracts and retains wate, The lower the fuel even the tank, the more likely you are to experiance water contamination. Water from he ar ende up in your ue ank and engine + Ethanol produced from oom, soybeans, sugarcane, and other organic materia. tls blended with gasoline (10% ethanol, 90% gasoline) to procuce E10. + Ethanol has less energy than gasoline, go it reduoes ‘uel ficiency. + Ethanol an excellent slvent. In high concentrations wil lean and dissoive deposi, rst inthe fuel system, ‘and some fue! tank materials. The dlesolved material can clog fitrs or pass tvough and lave deposts on carburetor os, +85, amicure of 85% ethanol and 15% gasoline, has beon inthe news recently. EBS is an atemative fue: its ‘ot gascline: Honda engines ae not designed or certified to run on EBS. + Refer tothe caner's manual fr your Honéa to get information about the recommended fuels and the curenty ‘pproved active + Tohelp pravent water contamination problems when using E10, always Keep your uel ank fll when sterng your equipment 2-4 SERVICE INFORMATION FUEL SYSTEM PREVENTIVE MAINTENANCE (IN SEASON) Fuel deterioration isa significant issue affecting carbueted engines. This may cause engine hard staring, fuctuatng for noile, hunting cr surging at ul rote, of low power. Curent gasoine formations have amid she ie when ‘exposed to heal and a, and can deteriorate in aslitia aso 4 weeks, So your equipments only used once @ ‘month o 0, storage preparation shouldbe considered Carburetor ‘When exp08ed o air or eat, the ful n @ carburetors lost baw begins to oxic, turning int a varish-ike or ‘gummy substance that wil restctor block te carburetor ts. All earburtar foal bows are vented othe atmosphere, allowing the fe! to oxidize ta slow, steady rato, Potential problems can be reduced by closing the fuel Valve anc running the engine ou of gas ater each use, Equipment Fuel tank ‘The gasoline inthe equipment’ tank's also expos0¢ othe at trough the tank's vent. To slow the deterioration of ‘acaine inthe tank, kop ae much a ae posible out of he tank by Keeping the tak fll uring periods of inact Fuel Storage Container saline should be stored in a clean, past, sealed container designed for fuel storage. Close the vent (equipped) ‘nd store the container aay trom direct sunlight a caol area possible. The use of meta ue containers is Giscouraged, as over timo, they can rst. the tiny parses of rst are trangpored nt the earouretor bythe fue, they ‘may block the tny passages in the carburetor. I ittakes moro than 3 months o use the fuel inthe container, we suggest ading a fel stabilizer to he fuel whan the ‘The Disinbutors Limited Warranty doesnot cover fel system damage or engine performance problems resulting fam improper storage. 2-5 SERVICE INFORMATION STORAGE (OFF SEASON) Depending on tho rgion where the equipment is operated, fuel formulatons may deteriorate and oxidizarapy.Fusl deterioration and oxidation can occur in as lite as 80 days and may cavee damage to the carburetor andor ful system. Gacoline wil oxcize and doerierat in storage. Old gascline wl cause hard starting, and itloaves gum deposit that ‘og the fuel syetom Ifthe gasoline n the engine dtorortes dung sorage, tho carburter ad other ful ajetor teomponens may need tobe senicad or rapiaced “The longth of ime that gasoline can be lfm the fue! tank nd carburetor without causing functional problems wil vary wit such factors as gasaine Blond, storage tomperatiros, and whathor the ful tanks partly er complctaly filed, Th atin partly lac tuo tan promotes fue! deterioration. Vary warm storage temperatures aceowato fuel {etoiration. Fuel detoeration problames may oecur within afow monte, oF even leas ifthe gacoine was rat fresh wine you filed the fue tank ‘The Distributor’ Limited Warranty ds not cover fel systom damage or ongine performance problems rocuing from neglectod storage proparaion. You can extend fs! storage Ife by sddng a gasoine stabilizer thet formulated for thet purpose, or you een aveld {ual deterioration problems by daring the fuel fark and carburetor, Service aocording to the table below: RECOMMENDED SERVICE PROCEDURE TO STORACEIING PREVENT HARD STARTING Less than 1 month 'No preparation required ee “Filth rsh gasoline. Add gasoline stablizo 1. Filwah fresh gosoine 2 months tot year 2. Add gasoline saber 3.__Deain the earbcetor oat bow 1. Drain the fuel tank and carburetor, 1 year or more 2. Change the engine ci 23, Lubricate the ovine. * Use Hondas ue stabiizer hats formulated fo ‘entend storage fe. Follow the instructions on the container, Fuel Stablizer, 500m! Part Number: CA66826 SERVICE INFORMATION Using a Fuel Stabilizer Use a fue stabilizer if the equipment wil be used inftequenly, but more than once a year To counteract the deterioration of gasoline, use Honda's uel tabiizor (608 page 26) al he recommended rae. The amount af stabizer ‘equted varies, depending on how long the ful wil be stored. Foiow the manufacturer’ instructions Isted on the fue stabiizeecontainee, the equoment is used les than hice month, you shoul Keap fuel ‘stabiizer Inthe equipment fue! tank at al imes. Be sure you run the engine for atleast 10 minutos after adzing the stabilizer. This allows the ‘Stablized fuel mode to reach and il the carburetor. Draining the Fuel ‘Tho fel tank and carburetor shoul be Grained for long term storage (one year or longer). Even fel stabilizer wil not prevent fel deterioration problems when the equipment is in longterm storage. The volatile companants of he us ‘nl vaparize and low et haf fank vent and earburtor ven, leaving gummy non-voatle deposts nthe Wel ‘system, In many eases, he equipment can simply be run out of fel, Or he fue can be drained from tha fal ank by removing ‘he carburetor float bowl dain bot (f appleable), leaving the fuel vave open, and draining the Wel nko an appropriate container fr proper disposal ‘The owner's manual describes the procedure for proper storage ofthe aquipment. See the STORAGE or HELPFUL ‘TIPS AND SUGGESTIONS chapter of your owne's manual 2-7 SERVICE INFORMATION EMISSION REGULATIONS REPLACEMENT PARTS “The use of nom-original equipment replacement parts may impal the electveness ofthe engine's emission control system. If such a replacement pats used in the repair oF mainlonance ofthe engine and itis determined that {auses afalure ofa warranted pat, any clams fr repair a he engine may de dened. the pat in question isnot related tothe reason your engine requites repar the claim wil not be denied. the use of aren-oriinal part causes the engine's emission level to change, you may be tampering (see below), ‘The easiest way to insure te proper parts are placed on the engine fs to use only Honda Genuine parts and have the jeauipmentlengine mode. ype, and srial number whan accessing the appropriata parts siagram, When replacing a afbutetor assembly, t may also hep to have the exvburtor ID number COMPLIANCE: TAMPERING “Tampering s defined simply as doing something that adversoly affects engine emissions Don't may th angino. Make all necessary angine adjustments and opais according tothe engine manufacturer's shop manuals and service bulletins. Manufacturers, dstibutors, and dealers ae held toa diferent standard on tampering than owners ofthe uipment. 2-8 SERVICE INFORMATION PILOT SCREWILIMITER CAP REPLACEMENT Removal ofthe limiter cap requires breaking the pt screw. Anew ple screw and lniter cap must be installed, 1. When the imitr cap has been broken of, remove the broken plot sere. 2. lace the spring on the replacement plot srew, an install t con the earburet, ‘3, Turmthe plot ser in unt itis ight seates, then tun the screw oul the required numberof tums, Retro the appropriate shop manual for carouretr plot ‘crow inital apening sting, 4. Apply Lctite® 638 to te inside ofthe Iter cap, then instal the cap sothe stop prevents the pilot screw from being turned counterclockwise, Be careful to avoid tuming te plot serew whl nstalng the liter ap. The pl screw must stay at i roquied satin, SERVICE INFORMATION 2-10 BB-TYPE BE-TYPE (aPPLICATIONS rd CARBURETOR SERVICE Ez soot 3a BF-TYPE oxo 3H Seo aren ow =) 3 ore aaa] [ows0sr Ie sere BI-TYPE BW-TYPE [aePucaTions Pace oman | HDA-TYPE [Sec rane caahoa w sae WYB-TYPE WYL-TYPE eC Tn 3H BB-TYPE GC135/160/190 - GS160/190 BB-TYPE 6C135/160/190 + GS160/190 ‘THEORY OF OPERATION Float Chamber Wien the float chamber emply, fel rm the fuel ank can flow past the float valve nto the foat chamber. As the {uel lvelis the chamber rises, the float ies witht. When the fat pushes theft vale into ts seat, the flow of ful ‘stops. As ful is dram aut ofthe foal chamber, the lat moves down and opens the fot valve, This cycle aecures & ‘conatant level of fl nthe float chamber. Main Circuit hen the thettle valve opens, a passes hxough the vent inthe carburetor’ tvoat. Because the ventur's lamar is smaller than th intake opeing, the ar speeds up asi passes trough. This increased air velocity produces low pressure atthe out of te mai nezze “The foat chamber is vented to the atmosphere (bow ven). Since atmospheric pressure ishigher han the pressure in ‘he venturi fuels pushed out ofthe float chamber, trough the main jet and ino the main ful nozzle. Alr passing ‘trough the aot mines wth fuel flowing trough the main nozzle’ ar bleed hoes, Ths rch mature ie then sawn It the ventur where it mixes with eve a to produce the final auel mixture, Slow (Idle) Circuit Win the theo valve is completely closed (le), engine vacuum (ow pressure) is proset athe pict cue inthe Intake tact. Atmospheric pressure inthe lot chamber then Tores fuel hvough the main jot and int the slow cult bypass. “The plot et controls fue fow through he slow circuit bypass. The fue then mixes with ar that is metered by the pt airjet. The resulting fuer macure then flows through the plot out ad into the intake tract. The plot serow ‘ontrls tne amount oul midure hat can tow trough the pst cute ‘Transition Circuit “The vansiton cuit suppis fuel othe engine during the transition fom the slow (le) circuit the man cet and vce whan the throttles opened sight, high veloc ale flows between the edge af he tvote valve and the transian ports, which ae located upstream of the plot out. The resulting iow pressure (vacuum) draws fuelair madre from the slow creut bypass trough the transon ports and into the intake tact, provding the proper fel charge for ow speed operation “The plot screw dose not ontalhe fuelair mature that passes ‘trough the tansiton pos | te throttle plate open farther, the vacuum atthe transition ports decreases. As a result, there is very ile flow tough these ‘tices, andthe ail mixture for mid- and highrepees ‘operation's provided almost completely bythe main cult 3-2 BE-TYPE 190 + GS160/ 160/ Go135/ 60/190 - GS160/180 CARBURETOR TROUBLESHOOTING INSPECTION POINTS “The Information in this chapter applies othe carburetor and fue! system only. Use the Troubleshooting Chapter ofthe ‘appropriate shop manual to confm thatthe fuel system ithe cause of he problem before using the tae below, © vagecton oder tse dssety Get onberemmnor etpege mmo stopeten Pa Syme [sy cove vate owaton Isodurn isso sgn mst one tof teen (cape pl out Kent wate so sen |stats ue ndrant ap [sty ort vate carton fmt rea option [Seopa mace fer 1 arpa aon freer ae Improper saan of mans pe Tr 2 1] |ssiecrmini longa jt ce = Fs ears, ‘Damegedcontaninated Nat ve seating sae Somme Fy tot operon, ol ons ot opee 7 ee ee eee) A ekg past te caro nas eh Lent aie * Si lage its, orn ote sha. [5 teeter Eni ting |: Great tte causes camber aesge Swat trasnng ‘Moin te Tetra eaten stom onto © eeesee| |e coaoeenoe cool pesoeseae| | Bodercoes wm |r faulv eke ceraton 7 ‘SSeeraase |_|: Wonamemtaae [ Maha, | Sotnirathemstoe acct) 34 BB-TYPE GC135/160/190 + GS160/120 CARBURETOR TROUBLESHOOTING INSPECTION POINTS (CONT.) Ortoarcnauser (stow encum ptoyamser @ vewrus ewe vave HO eke : taal i Manan ser oneice mor genew i @veoms wise eee ay eggasen, HS vee gnvdns Spy omen @rowr eyes AR BLEED HOLE @ron vive oe roar arm Fuonr cHanee 200 Quan ser 3-5 BB-TYPE GC135/160/190 - GS160/190 CARBURETOR REMOVAL ‘Your type may be difrent. Refer ta the appropriate shop manual fr carburetor removal and instalation sot eg eer eae SEE BF [Force] (rome) = —— ancrenen BAECS 3-6 DISASSEMBLY/INSPECTION BB-TYPE GC135/160/190 - GS160/130 4 Drain athe oat chamber fue into an approved container. 2, Clan the outside of the carburetor before csassembiy. 9. essomble an inspet he carburetor asinate bolow, Us 38m (Hh) ft abi serene to remove be mem Disassembly Inspection ‘BE-type carburetor shown. = ‘tom Tetean [Revioce| ‘The BE-type has some components that are not | Grectene pote noe tr coggi, Rinser ert caaetre ne OBE 7 OPE aween| Popo = aetreews| 6 | con perborate hich @ | oereerwwrennnen | O 2 a coamarine Ouautasre ‘Baer © [ceateersmsnan tran | O @ngron Browne O| Rae | O ~~ Olmarmmmans= | | @ © | Bareinaea e Le 8 esroum | [eee | Ts | sereaereem [0 Le ol Samana e '. OE of | T elgamevam” [Ole rues ora screw Bl en troniers ° sekoat Seam 16 i oaemeenone ° 37 BB-TYPE GC135/160/190 - GS160/190 CLEANING B-type carburetor shown. ‘The BB-type has some components that {ara not found on other Honda carburetors. [—): indicates parts that are tkely to be clogged; dean carefully. sr rest > ‘moore Roar wh ee ® rerea cara eles Sear |] Somme te sete Spay Car gh be Seilcaeta gocspopestes | lovpemey ©] pemptyeecenen ©) Sra. | emenanaraaace ©] sare tan rai fon @| Geant teat ae asa Se 3-8 BB-TYPE GC135/160/190 - GS160/190 CLEANING (cont.) (Use Honda Carbureto Combustion Chamber Cleaner PIN CAGE816 wth I's pesic spray nozzle to clean the pots. Some cornmercialy-avaable chemical carburetor cleaners aro very cause. These cleaners may damage plastic parts such 8 Crngs, floats, choke valves, and fost valve seats. Check the containor for instruction. if you are in doubt, donot use these pedis to clean Honda carburetors. Figh a pressure may damage the carburetor Use fow bressure setings when cleaning passages. 1. Glean te ets and passages wit Honda Carburetor Gleaner (PIN 08732-CC000). 2. Use low air pressure and dean the following passages anc pots: + Vent port + Plt serew hole + Ptatjot hole Maia ait jet + Transition ports + Plot aul + Main nozzle holder 3. Refor tothe jet rango chat onthe back ofthe Jot Cloanor Set (PIN O7PZ-0010108), an select the appropriate Clearing needle to remove any dust di, ee. hat romaine ‘ator Stop 1 and 2 Using @ etzaning needle thats to large may damage the carburetor. Never force 8 needle, and never use a needle With @bont or damaged tis. Due to manufacturing niranoas, it aye necessary to use a needle thats srt than the sghindgaed on the onan. 4. Bo sur to clean the trash port gent te sido of the carburetor throat near ihe ‘yotla velp. Hise pons ‘are locked, tha engine wi rough rata gist above ‘le. 5, Reassemble the carburetor caretly. Take care not to ‘overighten tha main ot 6, Insal he carburetor in ravers err ofits removal using now geskets where appropiate 7. Procood tothe Adjustment section (ext page). JETRANGE CHART B-TYPE GC135/160/190 - GS160/190 ADJUSTMENT Before making any adjustments: | + Verify thatthe goverer is properly adjusted before staring the engine. Refer tothe appropriate shop manual (Check thatthe thre and choke contls operate propery before staring the engine, | + Check that there are no fuel leaks before starting the engine. | Star the engine and allow it to warm upto normal ‘operating omperatue. Be sure that al engine CSpot re win spc and hora no ee oats ne ah, —, er le Speed Adjustment ay 1. ‘Startthe engine and allow it to warm up to normal c operating temperature 2. With he engine idling, tum the trate stop screw to ‘obtain tho standard idle speed, Refer to the appropiate ‘hop manual forthe standard idle speed specication. ‘Throttle stop sere + Tum clockwise rpm increases | + Turn countrcockise bm deceases Maximum Engine Speed Adjustment 1. Mave the trots to FAST. | DECREASE | WEREASE 2, Sta the angina, let warm up, and then check the ‘engine speed with the throttle sot FAST | 3, the engine speed isnot within speciation, bend the ‘governor sping arm tab, “Right increases spring tnsion and engine speed, + Left decceases sping tension and engine speed 3-10 BB-TYPE GC135/160/190 + GS160/190 Notes 3-11 BB-TYPE GCV135/160/190 + GSv160/190 BB-TYPE G6V135/160/190 + GSV160/190 ‘THEORY OF OPERATION Float Chamber \When he float chambers empty, ual fom the ful tank can fw past the fat valve into he float chamber. As the {ual ove inthe chambor ses, the float rises wth. When the Fost pushes the fat vaive nots sea, te Tow of ue stops. As fuels drawn out ofthe float chamber, the float moves down and opens the lot valve, Th cyee assures & Constant level ol fuel nthe float chamber. Main Circuit \Wnen the trot valve opens, ar passes though the venturi the carburetors treat Because the venturi iamator is smaller than tho inake opening the airspeeds up as ft passes through. This increased ai velciy Produces low presure a the ult of the main nazz. The float chamber is vented tothe mosphere (baw! vent). Since atmospheric pressure is higher than the peessure in the ventur, tues pushed out ofthe fat chamber, through the man Jt and into the main uel nazze. A passing through te ar jet mixes with uo owing through the main nazzes ar bleed Holes. This ich mature Is then crawn int the vertu whore it mixes with more ai to produce th nal aus mixture Slow (Idle) Circuit ‘Wien the throttle valve fs completly closed (i), engine vacuum (ow prossure) is presenta th pilot cuttin the Intake tract. Atmospheric pressure inthe float chainber then forces fuel fvough the main jt and Ino the siow dcut bypass: “The pot jot controls fel fow through the slow circuit bypass. Th fuel then mixes witha thats metered by he plot ait. The resulting fuer mixture then flows trough the pot outet and int the intake tact. The pt scxew Contos the amount ot tel mstre tna can tow through he plot out. Transition Circuit ‘The trarsion cult supplies fuel tothe engine during the transton from the slow (le) crcut tothe main ecu and vice |When the thot ie opened sight, high velocity air flows between te edge ofthe trot valve and the transition ports, ‘which ae located upstream ofthe pit out. The resulting ow pressure (vacuum) draws luol/ae minture from the slow Greut bypass trough the transiton ports and int the intake trac, providing the proper uel charge fr low speed operation “The plot screw does net conto! the fuel mitre that passes ‘trough the transtion ports As tho thot plate opens farther, the vacuum atthe transition pods decreases. Asa result eros very Ite flow tough these ‘tfcos, and the afl mixture for mid- and high-speed ‘operation is provided almost completely bythe main cult 3-12 BB-TYPE GCV135/160/190 - GSVv160/190 313 BB-TVPE GGV135/160/190 + GSV160/190 CARBURETOR TROUBLESHOOTING INSPECTION POINTS “The information inthis chapter appl to the carburetor and fel system only. Use the Troubleshooting Chapter ofthe appropriate shop manual cant thal he fuel system isthe cause of the problem betore using the table below, (©. tnpecton er are Sasser (3 Renn sre noun ot 9808 — — or == ; Pee E mem |S =eranog — | #8 ae 241 | pesmaemos Fees. [ER Rise smenn | BTA Bikes cca es eae ee | fe. gb lesa I San is Seen | ae seeeeros, 8 | ee Reeecomanene., |8| [Eee | [@ |oerrorastgescie nivetatcranber | © | [0 exemcemeea ore foe) |e eeenmnere 8 Cammmiors|_l[elakcmieccortectins | co (8 eored uber tr oem @ [> Hunting | oT Air leaking past the carburetor insulator casket tea age ean ete cseices’ J Sco =] feeea |. Power drops, rom amare: Seacoot te | Stearn a 3-14 BB-TYPE GCV135/160/190 » GSV160/190 CARBURETOR TROUBLESHOOTING INSPECTION POINTS (CONT) [BEtype carburetor shown, ‘The BE-type carburetor has some components that are not found on other Honda carburetors. © crows Lever @canauneron GasKer One Onin QO Float CHAMBER Ong © veruns © Hone vawe @ Mawar ser once @ worn wave © frncernetic © @noe—] ty @ rtost vaive seat @rvoarvave @manser @ rons an BB-TVPE GCV135/160/190 - GSV160/190 CARBURETOR REMOVAL ‘Your type may be diferent. Refer tthe appropriate shop manval for carburetor removal and installation, Reler to Section 6 for ypes wih ARCS (Auto Return Choke System) and ACS (Auto Choke System) Earn con Refs amouioe GASKET 2) IRSTAULATION ina oor aneani@aTune preter exsammsru0 Se _ oe TaRTHUMBER HOTLZOOT) gg 3-16 DISASSEMBLY/INSPECTION BB-TYPE GCV135/160/190 - GSV160/190 4. Din althe float chamber fue into an approved contanes, 2. Clean the ouside of he carburetor beoce disassembly 3. Disassemble and inspec the carburetor as indicated below. Use a 6 mm (1H in) fat cabinet screwesiver to remove the maine. Disassembly omer Inspection ‘heck esate nara PP arrecen @ oe © wmnoze: nner Quer —$§8 g§— Grow ave a | @nbe @Brioar cramser |@roredemmoen ‘iter ap ta ne pet ‘sew Ay steno ep ‘roto repacarien Goer. ise oe sm edn ‘Shc he ea nas mag ache raise 1 Gretta emer nare_| Sevetmavamae (Banctredon he onal (eck ne shat or enon mover @|e/e/e|e/e/elele ® a * ovr anges wn AGS AO Sen) 3-17 BB-TYPE GCV135/160/190 - GSV160/190 CLEANING Use Honda Carburetor!Combustion Chamber Cleaner wit its plate spray nozzo to clean the carburetor ports ‘Some commerciall-avaabla chemical carburetor cleaners are very caustic. Thase cleaners may damage paste parts suea8 O-ings floats. choke valves, anc float valve sents Check te container for introns you ae in ‘ub, do nat use hese proucts to clean Honda carburetors. {Nome} "ugha pressure may damage th carburetor. Use ow pressure settings when cleaning passages. 4. Completely tsassemtbe the carburetor except fr the pilot jt screw (P. 3-17). This cleaning procedure is Performed without removing te pilot jt sere. 2, “Clean tye main nozze thoroughly using carburetor cleaner, Appropriate size cleaning too, and compressed ar.Do | |S) mel use a weidhig tip cleaning needle wet cueaner > ‘avaarioee Using a walng tip cleaning neecle o a jot needle dats (oo large may damage the carburetor. Never force @ needle, and never use a need wi a beat or darmaged tp. Inspect the cents and side hols for damage or contamination by hlding the main nozzle up oh to vey they are deen, 3. Clean the main jetty spraying carburetor laner through, the et and using the appropriate size jet tering tool and ‘compressed af. Do rot use a welding tip cleaning needle Using a welang tp boning needle ora jot needle hate | 1EAMER, ——> to large may damage the carburetor. Never fore 8 reedl, and never use a needle wit a bent or damaged fi. Carefully inspect the main jt for damage or contamination 4, Clean the float valve soat using carburetor cleaner and comprossod a. 3-18 BE-TYPE GCV135/160/190 » GSV160/190 5. Clean the main jt and nozzle bore thoroughly using carburetor cleaner and compressed air wanueta Inspect the ini of the bore for contamination 6. Clean the plot et thoroughly by using the appropiate skze [-—————__— Jet cleaning too, carburetor leaner, and compressed a ‘The passage ls small anc easily obstructed, so repeat several imas, Its not necessary to remove he pilot sre a hs point. 7. Clan the high speed air passage wih caroureter cleaner and compressed a {@. Clean the float chamber vent hole with carburetor ‘esner and compressed ai 3-19 BB-TYPE GCV135/160/190 - GSV160/190 9. Reinstall he 56 mm screw covering the plat 10. Check the slow speed arplt screw channels or obstructions Spray carburetor cleaner through the slow speed ai passage. From the opposite end, confim theta steady steam of carburetor cleaner sprays out fam around the plo. Screw tip and ansiton ports. 1 itdoes not ow around the pilot serew tp, remove the plot scrow an clean the passage The plat serow rust be destroyed and replaced itis removed, It may be more ststlecive to replace the carbo 11, Reassomble the carburetor careful. Take care not to overighten the main jot. 12. Install the carburetor in reverse order of is removal using new gaskets where appropiate, 13. Procoed othe Adjustment section (next page), 3-20 Ba-TVPE GCV135/160/190 - GSV160/190 ADJUSTMENT oer Bofore making any adjustments ifthe plot screw was removed t must be property set before making any the ile pee axjustmant. Refer ‘he appropiate shop mancal + Very tha the governor is propenly adjusted before siaring the engine. Refer othe appropriate shop ‘manual + Check that he thotle and choke controls operate propetly beter staring the engine, + Check that hore are no fel leaks before staring the engine + Start the engine ard alow itto warm upto normal operating temperature. Ba sure that all engine er ‘components ae within specteations ana there arene Eager" fie leaks Ino the intake path oe Idle Speed Adjustment ‘Types with xed tote do not have a throtle stop screw. 4. Start the engine and allowitto warm up to normal ‘paratng tomporatue 2. ‘With he engin iting tum the throte stop screw to jbtain the standard idle speed, Refer tothe appropriate ‘Shop manual forth stander cle speed spectieton, ‘Throttle stop screw: + Tum docks. rom increases + Tum counterclockwise rom decreases enue ar Maximum Engine Speed Adjustment ——aeveron sine Ta ‘Types With Control Base - Throttle Cable 1. Move the thot to FAST. | | 2. Check the clearance betwoon the choke arm and control THROTTLE 3, The contol lever shoul just contact, butt move, the | choke arm, UY 4, fnecassary, loosen the thote cable clamp to achieve the pope oto, : 5. Stat the engine, ett wa up, anh hack he <= engine speed wit the tate set FAST ae ae 6. Ifthe engine speed is et within specication, bond the Seeeo Spee govaror spring arn tab. —————— * Leflincreases spring tension and engine speed. + Right decreases spring tension and engine speed. + Typos With Fixed Throttle -No Throttle Cablo 4. Chack the maximum engine spoed. Retr to tha appropiate shop mana or maximum lengine speed speciation 2. edustmentis necessary, bend the governor sping tb a ‘on the title carta plato very sight. + Leftinereases sping tenslon and engine spsed + Right decreases sping tension and engine speed 3-21 BB-TYPE @150/200/300/400 BB-TYPE 6150/200/300/400, ‘THEORY OF OPERATION Float Chamber \Wnen the float chamois empty, us tom the faa tank can flow past he fot valve into the float chamber. As the ‘uct ieval in the chamber rises, the fost rises with i When the oat pushes the float valve ines seat, the fow of fue ‘ops. As fuels drawn out ofthe float chamber, the fost maves down and opens the fat valve, Ths cycle assures 3 Constant level of ful nthe feat chamber. Main Circuit when the throtle valve opens, air passes through the ventur inthe carburetor’ thyoat. Because the venus diameters smaller than he intake opening, the ar speeds up asl passos through. Ths increased ai veloc rofuces low pressure atthe outlet of the main nazz. “Tho float chamber is vents tothe atmosphere (bowl ven), Since almosphetc pressure ishighor than the pressure in ‘he venturi felis pushed out ofthe float chamber, trough the main jet and into tbe main ful nozzle. Alr passing ‘through tho ai jot mixes wth fel Towing trough the man nozzle’ ar lewd hoes, This ch mixture is then aan into the vent where it mixes wth more ato produce the final asl mixture, Slow (Idle) Circuit when the thro valve is completely closed (le), engine vacuum (ow pressure) is present atthe pilot out inthe intake trac. Aimospherse pressure inthe float chamber then frces fue rough the main et and ino the slow crcut bypass. ‘The plctet controls fe! ow through the slow cult bypass. The fuel hen mises wth a that is metered by the plot aiet The resulting fuel/air mixture thn flws through the plot outlet and into the intake tact The pilot sew ons the amount or uel mature tat can How tough the plot eile. ‘Transition Circuit ‘Tho transition circuit supplies fuel to the engine during the transition fom the slow (ie) cult to the main crcut and view When the teat is opened sight, high veloc aie ows between the edge o the throtie valve and the transition pots, which ar loested upstream of the pit out. The resulting low pressure (vacuum) draws fualirmicure fem the slow creut Bypass through the wansiton ports and into the intake trac, providing the proper uel charge fr low sped operation. ‘The pit screw doss not conto the fuer mixture that passes trough the vansiton ports. As the trl plato opens farther, the vacuum atthe transition ports decreases. As @ result hers is very ite flow trough these beens, and the ail mixture for mide and highspeed ‘operation Is provided almost completely bythe main cut. 3-22 BB-TYPE @150/200/300/400 (stow cincurr) peamacded) ; / [ames St oe | ‘TwROTTLe VALVE, tumcncuy ruorouner a ie cee — aso voit 3-23 BE-TYPE @150/200/300/400 CARBURETOR TROUBLESHOOTING INSPECTION POINTS “The information in this chapter applies tothe carburetor and fue! system only. Use the Troubleshooting Chapter ofthe appropriate shop manual o contr tat the uo system fs he cause ofthe problem before using the table below. [ctogged pilot outer Pa eee —— See FH Se | ee ay 8 LAP ERS [LES eee leaded nase [incr naatien orb aunt |Xtearg ough onan aso rauor Fete ran rng man toe Samet robe © 999909269 G99) peeoaseeo or. ie *Gihahenens| oe Forconnatancntetporteteawe | Fray cure genta pope ate) Fry eaten fo 068 rt pate Sm nba) : © @aceso [era ling es he bein nein eastat * Lean sn mre rae sg Setting tt te ber ssege 1 Svat na Soa trong rat soe 1 Sateen elevation Resin pte ad fe ‘Goypat coins Fay cots eperton |__| Hag en emp, Viera eas ho hai anew Dotted gsaine nator! 3-24 BB-TVPE G150/200/300/400 CARBURETOR TROUBLESHOOTING INSPECTION POINTS (CONT.) © wswaror casKer One, Orvonrcammeer i = Overrun O drone wuve © mannozae @uorouner Sn GPE ose: re) Fl pr @ AIR BLEED HOLE a ‘@ row vawe sear non Drowvne — & posrana @uanser B-TYPE G150/200/300/400 CARBURETOR REMOVAL be BB-TYPE G150/200/300/400 DISASSEMBLY/INSPECTION 1 Drain al the fat chamber fuel into an approved container. 2, Clean the outside of he carburetor before dsassembsy 3. Disassemble and inspec the carburetor as indicated below. Use a 6 mm (14 in) at cabinet screwdriver to emove the main et Disassembly eeu row screw @ehne Inspection ‘Oe he pt ele eon ‘heck ea teed ee coupe ‘Seca rose reo Grow ve —fy = pes © atte ee yessat ee Soerages ‘aa man Per hes fective e|e/e/e/e/elolelo eae ctaner tr carson @ 3-27 BB-TYPE 150/200/300/400 CLEANING ee | eee BB-ype carburetor shown, wo me, ‘The 88:1ype has some components at |_| Sow vat {re nol found on other Honda carburetors. GQ] Ronee onanism [1]: treats parts tat ar hay obo pe Cogged clean careful. | (@rucrsonew Sear” @ 13] vae—— | 3-28 BB-TYPE G150/200/300/400 CLEANING (cont.) ENGINE BLOCK SE: Use Honda Carbureto'Combuston Chamber Cleaner Transmmon PIN CAGSB16 with’ paste spray nozzle clear the ports Ports ee Some commocilly available chomicl carburetor cleaners are ory eausto. These cleaners may damage paste pats Such a8 ‘rings, sis, choke valves, and Noa vave seats. Check he en contaer or stuctons. you ein doubt, donot use these prose o loan Honda carburetors RB) ewe aor High ar pressure may demage the carburetor. Use low Serious prSssiresetngs whan cleaning passages. Zz 4. Clean thoes and passages wth Henda = fotoee Carpursoricembuston Ghana Cleaner PIN CABES16 2. Use low air pressure and clean he folowing passages and | /AMCLEANER SDE pons: 6 + Vert pot © + Plt Soew hola D + Pltjethole = = Main at hor ant EER rE Pee * Transton ors + Pteutot Main nozzle holder “JET RANGE CHART |. Refpeto the jt range chart on the back ofthe Jot Clr ‘et PIN 07PZ-0010108), an select the appropriate emma asenesr omentum ara BE-TVPE iGxaao DISASSEMBLY/INSPECTION Remove the ECM, throitle and choke motors, middle gear, choke reduction gear, motor pat, and the motor case washer) ew (eneme conrROL NODULE) (ean CENTER SHAFT 3-75 BE-TYPE iGxaao DISASSEMBLY/INSPECTION (Cont.) 4. rain allthe lest chamber fuel into an approved container 2. Clean the ousise ofthe carouretor beter cisassombly. 3. Disassemble and inspect the carburetor as indicated below, Use a 8mm (14 in) ft cabinet screwdriver remove the main jet. Disassembly Inspection ‘BE-type carburetor shown, No| tam ‘Giean _[Repioce The BE-type has some components that are not @ | Crack the plot oles for clara. — | O) ‘eantoncter Monee TMU FUEL AE TIPE: | | @ | Sustain orate sore e seemecen eee — @|eraserwiecmannen | O Piste @|codwanecate TO LEVERSPRING © | Gree teeth er coos. fe) Olmmmac = | [e ae © | oratedaeteseset e sane WE olsen, | |e om Ud @ | emer te oar care e Opeome., | areomenrene 1S Fitting olaeneiae” (0 fe | @ | aan e @reorscnn gS = 7 Es “9 K 8 . ono ¥/ a onker | cetranrony rece ee @ ele CS — ra currarer a Sed conn ‘ck ne nah argh nore 3-76 BE-TYPE 10xaso Disassembly Inspection Eager som i ca Fo The SE-ypetas ope cmponarts at ar not @|omcrermmroeeiremia | O | @ | cree tt Oar er ane, e i egumgensen ooo Sua 6 | aanwmawews [0 Omeme—— SU © [SEE [Oo y\erore | Operant e ome He : aap see | [ol Samco, e ashen a) rox @ | creck ne orm tor samen. e @| Sar aememmaie 1G - A | eas fo \ iy | [olsumarem” lo Le Gener A Gnowewecn | |G | Ragman weer e oo] Se Saeco se ee 3-77 BE-TVPE. iGxaao CLEANING. Giaaner / i rua curentes @SE0AENT CUP 3-78 BE-TYPE, ia@xaao CLEANING (cont.) ENGINE BLOCK SDE: Use Honda Carburetorombuston Chamber Cleaner sseeate IN CABSO16 wath paste spray nozzle to clean the ports sone ‘Some commocilly-avallable chemical carburetor cleaners are very eauste. These cleaners may damage paste pats such as, (Oxings, floats, choke valves, and fost vate seats. Check the container fr instructions. you are in doubt, 60 not use hese produits to clean Honda carturetrs, Fgh air pressure may damage he carburetor, Use low pressure setings whon clearing passages. 2 ‘Clean te jets and passages win Honda Garburetor/Combustion Chamber Cleaner PIN CASS916 Use low ar pressure and clan the lowing passages and pats: + Vert port + Plt serew hole + Pit jet hoe + Main air jet + Traneton porte + Pit outlet + Main nozzie holder Refer othe jetrange chart on the back ofthe Jet Cleaner Set (PIN 07P2-000108}, and select the appropriate inatestes pants that ae ikely to be dogged: clean cartuly ARE pwc ain paet y* wae & 2 SPICY ox, abr 2 Iie-o |“ ®|_ clean the pot ar torte. Soo” S| See. lcm —— : | sow d | Seed @|_cuntenavacetem | | Sertetaintmmsnn | Sarr 5 cote "lier cp. Repce ope oem 3-104 CLEANING (cont) Use Honda Carburetor/Combustion Chamber Cleaner Pn CAGEO16 wih ts Plast spray nozzle to cloan tho pot. ‘Some commercaly-avaiable chemical carburetor cleaners are very eavale. These cleaners may damage plat pars such 2 (Cxings, floats, cnoke valves, and fot valve seats. Check he ‘container for structions. you ae in doubt, dont use these products o clean Honda carburetors. NOTICE Figh ar pressure may damage the carburetor. Use low breseure solings when cleaning passages. 1. Clean the ots and passages with Honda CarburetoriCombusten Chambe Cleaner PN CAOEEIS repr hss fo following passages and + Plot serow hole + Plot jt note + Maina jet + Traneon ports + Plt outet, + Main nozzle holder 8. Refer the jet range chart onthe back of he Jet Cleaner Set PIN 07°Z-0010106), and select the pproprate leaning needle to remove any dus, dt. et hal main ‘afer Stop 1 and 2 Using a cleaning needle that i too lrge may damage the carburetor Never force a needle, and never use a needle ‘wah a bento damaged te Due to manufacturing iclerances,itmay be necessary to use a needle that Is smaller than the one indeated on the chart 4. Be sur to clean the transion pot iecaledin the ide of the carburetor throat near the thot valve these pots tare blocked, he engine will un rough e stl ust above ie, 5. Resssonble the cefduetor carey. Take care tf overtighten the main ja 6. Instal the carburetor in reverse order ots removal tas new gaskets where appropta, 7. Proceed tothe Adjustment so ADJUSTMENT ‘Thore are no adjustments wi ti ype of carburetor, aroun TSS JET RANGE HART 3-105 BF-TYPE G100K1 BF-TYPE G100K1 ‘THEORY OF OPERATION Float Chamber \Wen the float chambers empty, fue ftom the fue tank can flow past the fot valve int the fost chamber. As the {uel ove inthe chamoor ses, tho float isos witht. When the flat pushes the float valve ino its seat, the flow of fuel stops As fuels arawn out ofthe foat chamber, the Rost maves down and opens the fat valve. This cycle assures & Cconeant love f fuel nthe fat chamber ‘Main Circuit \When the tre valve opens, sr passes trough the vent inthe carouetos throat. Because the venturs iamear is smaller than the intake opening, te airspeeds up ask passes through. This increase ai velocity produces low pressure at the outlet of the main nozzle. ‘Tho float chamber is vented to the atmosphere (bowl vent). Since atmospheric pressure is higher than te pressure in ‘he venturi ue is pushed out ofthe feat chamber, tvough the main jt and info the main fol nozzle. Ai passing {trough th aot mixes with ul fowing through the main nezzie's air bleed holes. This rich mocure is then drown inte the ventur where it mixes wih mere arto produce the Final ave mature Slow (Idle) Circuit \wmon the tote valve is completely closed (se), engine vacuum (ow pressure) i present athe pilot out nthe Intaka tract Atmospharie pressure in the fat chamber then foros ‘uel through the main jet anc int the slow crit bypass. ‘Tho plot ot controls fuel flow through the slow circuit bypass. The fuel then mixes with ar thas matered by the pt ‘ale. The resting fuel bare then flows through the plot out an into the intake tract. The pit crow ont the amount ful mature tat ean flow trough ie pot Outet Transition Circuit, ‘The transtioncrout supplies fue to the engine uring the transi fom the slow (le) cuit to the main ccult and vice When the trate is pened sgh, igh vlosty aie flows Detwaen the edge of he thot valve and the tanstion ports, which ae located upstream of the plot oulet. The resutng low pressure (vacuum) eraws fualar modu rom the slow creut bypass through the vansiton ports and ino the intake trac, proving the proper uel charge fr low speed operation ‘The plot screw doos not contol the fuer mixture that passes through the tanston ports. | the ttle plate opens farther, the vacuum at the transition ports decreases. As a result thee is very ile flow though these bfices, andthe ail miure for mide and higespess ‘peraton is provides almost completly by the main elt, 3-106 3-107 BF-TVPE G100K1 CARBURETOR TROUBLESHOOTING AND INSPECTION POINTS. “The information in tis chapter appli othe carburetor anc fuel systom only. Use the Troubleshcoting Chapter ofthe ‘appropriate shop manual to cont thatthe uel system Is the cause of he prabiem before using te table below. © eagecton er tore dansety (8.20 Reson rer sno nn page cle Fost aera ve cowaton j cope peo {add ats sop eren 13 [fatjreth ane oecsen “ene? emaoos at 8 [ese ote tt caaton Roose gedaan iting Pea ran ca rat Soames te lng tt Fy [eemetmani lara map Sogpe et on srsghar vet eee|peeoeaoes © 85992800 me HH See 1 em | [Sear ene ae Hg [sete nen een ee \ Gacane wae Fay chamber sk Groot nae) ome : (Shei ocimsowee | & Elarormmmionin | © fase pecans cage eon [Se Stree a, [Restricted poet oy Pagemiem] Faaparawm aaa a oe Bie Facer J+ wrong man jet size nen ine She cation 3-108 BF-TYPE G100K1 CARBURETOR TROUBLESHOOTING INSPECTION POINTS (CONT,) Onsuaror © Shen © racer we _——Manencur, @wnprseronnce fp @morser e one @ovenss @row A row, || @nwarné me Ouee Ee oone @pwornésrer —/] ce Loar cuameeR 8007 uit i) Obnmc 3-109 3-110 BF-TYPE G100K1 DISASSEMBLY/INSPECTION, 1. Drain al te ost chamber fu nto an approved container. 2. Clean the ouside ofthe carburetor before disassembly 3. Disassemble and inspect the carburetor as indicated below. Use a6 mm (1M in) fat cabinet screwetver to remove the main et. Disassembly Inspection Omer @ | crea mesterttaetrassoes. | O aitesia Oe One i Bone ricer Semana @ | ercortwonnnan | O a © | omaoewrmaeriraaine | O. : Ores | | © | Saw paket snore ° OE aa e arn coe \ 1 @ | Beerametcasas” e @onns Gren e | TS [crac set erect nent e spre oo [@ | cxiergerroraime unser @ [Bagcrrncoore e @norycwaes | [@] Sask manminaoe o On] @ | Serctaten tsps ole oer @ | eesgeion ones e sao taegemem 1G ae © | aratecectrtomen e @ | crete ge rae e Elan) 3-111 BF-TYPE G100K1 CLEANING | B-type carburetor shown. tem Ponca Al ‘The BF-type has some components that ‘Slow Circuit ote ronal found on shor Honda carriers GQ] tare toon nt ton te (1): indoates pats that re Maly obo ma Sef Sean coy EO @) PILOT, @)_ coca the pil itt exon Coane omer ‘RIE! | | Clean te plot tet a @| “Siuctstteie ante | mrmaeten O) fenton | secs ©) srmecnirtcan, = | om a= sf Sree @| cme ra pte Ol Severe | iat @| Seototonntmandoat | Got | cietnionte “The ploecew rut to token evaroved on rash lis ce. Reps lt se 3-112 CLEANING (cont.) Use Honda Carburetr!Combuston Chamber Cleaner PIN CABEB16 wi I's plaste spray nozzle to clean the pots. Some commercially-avalable chemical carburetor cleeners are ‘ery caustic. These desners may damage paste pats such as, (ngs, floats, choke valves, and foat valve seats. Check the ‘container for instructions. Ifyou are in doubt, donot use these products to clean Honda carburetor, Fgh air pressure may damage th cerburetor. Uso ow pressure setungs when Searing passages. 1. Clean th ets and passages wih Honda CarburotovCombuston Chamber Cleaner PIN CAS6D16 2, Use low air pressure and dean the folowing passages and pons: + Vent por + Blo crow holo + Plott hole + Main ar jet + Transiion ports + Pilot outlet + Main nozzle halder 3. Refer tothe jet range chart onthe back ofthe Jet Cleaner Set IN 07P2:0010106), and select the appropriate loaning noodle to remove any dust, dit, ee hat mains after Step 1 and 2 Using @clegning noodle that i too large may damage the ‘carburetor. Neve eve a needle, and never use a needle ‘wth @ bent or damaged to, ‘Due to manufacturing tolerances, itmay be necessary to sea needle thats smaller than the or indiated onthe char. 4. Bo suo to lean the ransiton port located inthe side of ‘the carburetor throat near the three val. I these ports a0 bleckod he engin wil run rough e tall ust above id, 5. Resssomble the carburetor carefully Take care not ‘vertghtan the main et Install the carburetor in reverse order of ts removal using now gaskets whore appropriate. 7. Proceed tothe Adjustment section (next page). BF-TYPE @100K1 ADJUSTMENT Before making any adjustments: Verity thatthe govemors propery adjusted before stating the engine. Refer othe appropriate shop manual Check thatthe thro and choke contrls operate propery before starting the engine. + Chock that hore are no fue leaks before starting the engine + Start the engin and allow it to warm up to normal operating temperature. Be sur that all engine components are lithin specications and there areno ar leaks into the intake path IDLE SLOW SPEED ADJUSTMENT UNDER NO LOAD Uso the thrtte stop screw and plot screw (non-certfid engines) 0 adjust the ile sow speed ‘Throttle stop serew: + Tum docks. rpm increases + Tum counterclockwise... pm decreases Pilot screw (non-certifed engines): Reler tothe appropriate shop manual for adjustment and reassembly procedures, + Tum clockwise Jeane fel mixture + Turn caunterclockise her fuel mature Idle Adjustment (1) i the engine of, tum the thot stop screw clockwise untlt contacts {he trot lever, and then mae 3 more tune to open the trate pats Be sure the thot lever is touching the end ofthe screw, “Tum the plot sow clockwiso unt ighly seat, and thn back tout the numberof tums epected inthe appropiate shop mana, @) rig ‘Start the engine, and tt warm upto normal operating temperatre |Wnhen the engine is warm slowly tum the tote stop screw countercockwise unt the engine is running a the standard ide speed pected inthe shop mana. ‘Tum the pilot screw (non certified engines) in or auto obtain the highest or scxew engine rom, 19 the pt screw may damage th carburetor. ® @ (6) Ropoat stops (3) an (4) above unt the plot screw (non-certied engines) seting I a8 close as posibe to the dard idle spoed, {tthe plot sore (non-cetfied engines) must be tured more than one tun neither drecton from the shop ‘manual specication, the carburetor may have a blocked passage. 80 sure all air and fuel passages are clear betore proceeding. (6) Adjust the trot stop screw o obtain the standard idle specs. 3-114 2. MAXIMUM SPEED ADJUSTMENT UNDER NO LOAD ‘Set the throttle lever tothe maximum speed positon Maximum Speed Adjustment (1) Start the engin, and lett warm upto normal operating temperate, When ‘he engine is warm, tum the control over adjusting sew untl the engine |S running atthe specied maximum speed at fl thot, (2) Close the thot, ane then stowiy open it again, (9) Ithunting occurs as te thro is opened, adjust the pilot screw (non cerfied engines), (4) Check tne ile sow speod, and adjust he throttle stop screw necessary. BF-TYPE G100K1 3-115 BF-TYPE, Gx100 BF-TYPE ext00 ‘THEORY OF OPERATION Float Chamber \Whon the flat chambers empty, uo from the fue tank can flow past te fot vale int the oat chamber. As the fel level inthe chamber ries, the Moat sas witht. Wen the float pushes the fat valve ino its sea, the lw of ful stop As fli drawn out ofthe Foal chamber, the lal moves down and opens the fat valve, Tis cycle assures & Constant evel of fel nthe fat chamber. ‘Main Circuit \Wnon the trol valve opens, ar passes through the vont in tho carburetor’ throat Because the venturs siameer i smalier than the intake opening, te ar speeds up 98 passes trough. This increase air velocity racucas low pressure a tho outa ofthe main nozzle. ‘The fot chamber is venta to the atmosphere (bow vent). Since almospheric pressure is higher than the pressure in the venturi, fuels pushed uo the float chamber, trough the main et ana ito the main ful nozzle. Alr passing through the aire mixes with uel Towing through the main nezze's air bloed holes. This rich mintureis then crawn Inf the ventur where mixes with more ar to produce te final are mixture. Slow (Idle) Circuit When the trate valve is completely closed (cle), engine vacuum (low pressure) i present at he pio out inthe intake track. Atmosphere pressure inthe lol chamber then foes fuel hough tne ma jt and into te slow cuit bypass. “Toe plot ot controls fv! ow through the slow cult bypass. The ful then mixes wih ar that is motored by the plot let. The resuling Tuell minture then Rows through the pit oulet and into the intake tract. The pit screw Controle the amount of fuel moture tat can fow tough the pot out, ‘Transition Circuit ‘The Wanston cuit supplies ue tothe engine ding the transit fom the slow (le) cult to the main creut and vce men the teat is opened sight, hgh veloc a ows, Dbetwaen the age ofthe thrette vave and the transon ports, ‘which ae leated Upsteam ofthe pt aut. The resulting Low pressure (vacuum) Graws fulir micure fom the slow circu ‘bypass through the transition ports and into the intake tac, proving the proper fuel charge for low sped operation. The plot serew does not cont the fuer mixture that passes through the tansiton ports. ‘As the teat plate opens father, the vacuum a the transition ports docreases. As arcu. ther is vary ite fw through these ‘peation is provided almost completly bythe main exeul 3-116 BF-TYPE @x100 3-117 BF-TYPE Gx100 CARBURETOR TROUBLESHOOTING AND INSPECTION POINTS. “The information in this chapter apps tothe carburetor ane fuel system only. Use the Troubleshooting Chapter of the appropriate shop manual to confirm thatthe fuel system isthe cause ofthe problem Bafore using the table blow, Irspecn ocr aes dessa ($2 Reena sno on nn Pape nsgncton Pol Smo Fly cote vav pan pect fences ote op ew teoreon materi ne Fay Brow ve peeson [Scop ahi | Cin sr at 4 fears — td git epaiare eset Hl eaeanes ae : Eee er ree EY ees Fase carmen ene = ee igemrteneencna Bererncatoane SRE cotton a a ee © [eco © seeoea| |e ceaeeeaes ooc|fpecceseso Serums | Sele fen ‘fe [tone [ame Seam Fea coer oe Faulty choke operation + Icing (Low ambient temperature, | Seca on eons 1 ieee 3-118 BF-TYPE GxX100 CARBURETOR TROUBLESHOOTING INSPECTION POINTS (CONT) P88 © wewaron a One ae — MAM CREUT.—___.-D MANAR IT RIE [7 omerer (YY | @nom \ i iN Oa \\ ¢ BO cine tO '@ wanier ® wrorné stor wave FLOAT CHAMBER BODY. ee @ Pura ser 3-119 BF-TYPE Gx100 CARBURETOR REMOVAL ‘Your typa may be different, Refer othe appropiate shop manual for carburetor removal and instalation, ~ "Reatencotnsot 3-120 BF-TYPE Gx100 DISASSEMBLY/INSPECTION 1. Drain al he float chamber ful inte an approved container. 2. Clean the outsie ofthe carburetor belore isassemby, 2. Disassemble and inspect the carburetor as indicated below. Use a 6 mm (1 ln at cabinet sereweiver to Femove the main jot Disassembly Inspection / |} [se [exon [Reve Og Orn © [cmttermamnonom | O oo sew | [| Beason . aren car ee == > NS @|aaewntcanun | O Opmome 5S @| ceckie arses ras toreooora. | C | OE ce) Ore Olzameumma | |e owns © | Bratemetsreta e sl unite | [O [senses . @mner—_ 1B © wae © | Exieaigrm=ms TS © | Sate two i ence POI na @ | Seman fo) Snegowen | [Q[aantiam [O|@ Osean @ | eaten wera e : Sean 1S a — ones : er | @ | omen peer e 3-121 BF-TYPE @x100 CLEANING {BF-type carburetor shown, = come ‘The BF-type has some components that {Beeld Sree Gund on ates Honda carburetors Torta 1: nese part ta ra ty be OQ] feaetenin mtn e | PEELA . OQ jo pr} Qe lees O| Semeevetena — toy | [0] FEE morse ° i Se are @ | tek Ne | Settee © smeesy| |©| SemineesSgarvocstac, | on (S yanwozzie | | Low prossure | Se | aayo | |= 7 | @ |_cean ne man iene, | Quaveeder re G. |8 [eeceereronstonne | rere ane ‘hier dpRepce he roses 3-122 GX100 CLEANING teont) Use Honda CartureoeC amon Chamber Clesnee NONE BLOCK SE: PN CABEO‘ wih ds lacs pea hezl te oan tho port, reansingn pasa Some conrosiciahy-avsibie csi carburetor Cleaners ore | PORTS < Por ‘ery eaube. Those deaners may damage paste pats such as Ccrings oats, choke valves. and Feat vatve seals. Check the pani container fr nstetlons. you are dou, donot use these phen, we products to clean Honda carburetors. ber igh ait pressure may damage the carburetor. Use low mor prune seins when oorng passages. = ie 1. Glean toes and passages wah Honda Nome ‘CarbuetovCombuston Chamber Cleaner PIN CABBS16 an DER : Gleaner [ESS 2. Use low ar pressure and clean the following passages and Soe: a pons + Vent port + Plot sorew hele @ 9 + Plott hole + Maina jet P10T SRIF wan er + Traiton ports + Piotoutet + Main nozae alder 3. Refer othe jet range chart onthe back ofthe Jat Cleaner ‘Set (PIN 07JPZ:0010108), and select the appropriate ‘leaning needle to remove any dust, fet. hat erains ater Step 1 and 2, Using a cleering neeste that i foo large may damage the carburetor Nover force a needle, and nover use a needle wih @ ben or damaged tp. Due to manufacturing tolerances it may be necessary to 4. Be sure to clean the translon ports located in he side of the carburetor throat near the tote valve If these ports ave blocked, the engine wil run rough or sia just above ie. 5, Reassemble we carburetor carefully, Take care rot to ‘overtighien the mai jet. 8. Insal he carburetor in reverse order of is remove! using new gaskets where appropriate, 7. Proceed tothe Adlustment section (next page) BF-TYPE Gx100 ADJUSTMENT Botore making any adjustments + Verify that the govern is properly adjusted belore starting the engine. Retr to the appropriate shop mans + Check that he thote and choke contrals operate property before stating the engine. + Check that there are no fuel eaks befor starting the engin, | Start the engine and atow ito warm up to normal operating temperature, Be sure that all engine componens sre Within pectieatons and there arena ar lasks into the intake path, 1 dle slow speed agjustment under no oad Use the throte stop serew fo aust he ie stow speed Throttle stop screw: += Tum clockwise. rpm increases + Tum counterclockwise rom decreases IDLE ADJUSTMENT. (1) With the engine of, tun the tote stop screw clockwise unit contacts the trae aver, and then make 3 more tums to open the trot pat, Be sure the thot lever tavching the end ofthe sero. (2) Stat the engin, and ett warm up to normal operating temperature (6) Adjust tho thot stop screw o obtain to standard ide spoed. 2, Maximum speed adjustment under no load oar Sat he ttle lever to the maximum speed poston, MAXIMUM SPEED ADJUSTMENT (1) Start the engin, ad lett warm up to normal operating temperature {2) Loosen the lock mt (3) Turn the contro! ever adjusting screw unl the engine is running a the specified maximum speed at ful thet (4) Tighten the lock rut (6) Close the thot, and then slowty open again 3-124 B-TYPE Gx100 Notes 3-125 BF-TYPE GX100 (RAMMER, BOWL TYPE) BF-TYPE GX100 (RAMMER, BOWL TYPE) ‘THEORY OF OPERATION Float Chamber \Whon the flat chambers empty, ue rom the fue tank can flow past he float valve Into the fost chamber. As the {uel evel inthe chamber res, the float ies witht. When the float pushes the foal valve into its seat, the Row offs stops. As fuels awn out ofthe fost chamber, the fost moves down and opens the float valve, This eye assures a ‘onetant love of fel the fat chamber Main Circuit \Whon the trot valve opens, sr passes through the venturi the carburetor’ trea. Because the venture ameter is smaller than the intake opening, tho alr speeds up ast passes trough. This increased air vlocty produces low pressure a the outlet ofthe main nozzie ‘The fost chamber is vented tothe almosphere (bow! vent). Since atmosphere pressure is higher than the pressure in ‘he venturi uel is pushed out ofthe Neat chamoer, trough the main jt and into the main uel nozzle. Air passing trough the ait jet mixes with uel flowing through the main nezzle' ai bleed oles, Ths rich mixture is then craw int the ventur whore it mixes with mere arto produce the final aval mire Slow (Idle) Circuit When the ttle valve ls completely closed (le), engine vacuum (ow pressure) is presenta the pilot outlet inthe intake tract Atmospheric presaure inthe fat chamber then forces fuel through the man jt and int te slow cult bypass. ‘The plot jot conte fuel flow through the slow ccut bypass. The fuel thon mixes with ai that is mtorod bythe pit aj, The resulting fuer mixture then flows through the pot cult and info te intake tact, The plot sew Contote te amount ffl mista tat can few trough tne plot outlet, Transition Circuit hi ‘The transiton crcl supples fuel to te engine during the transi from the slow (i) cuit the main Grcult ana vico \Whon the ttl is opened sight high vloaty ai flows betwoon the edge ofthe tote valve and the transition pers, which ae located upstream of th pt cult. The resulting low pressure (vacuum) draws fuelalr micure fom the iow creut bypass through the ansiton ports and into th intako Wat providing te proper uel charge fr low speed operation. ‘The plot screw does not conto the fuel/air misture that passos tough the ansiton ports As te ttle plate opens farther, the vacuum at the transition ports decroases. As a result, there is very file flow though these ‘nflces, and the ale mou for mi nd high speed ‘operaion is provided aimast completely by the man crcut 3-126 BF-TYPE GX100 (RAMMER, BOWL TYPE) 3-127 BF-TVPE, GX100 (RAMMER, BOWL TYPE) CARBURETOR TROUBLESHOOTING AND INSPECTION POINTS “The information inthis chapter applies tothe carburetor and fal system only, Use the Troubleshooting Chapter ofthe appropriate shop manual fo con thatthe fel systm isthe cause of he problem before using the tale blow. © repro rt nny

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