4 FUEL SYSTEM CIRCUIT D’ ALIMENTATION KRAFTSTOFFSYSTEMFUEL SYSTEM mm (1.0 ka-m, 7 feb) Do e 8 ts Om fool 4-0FUEL SYSTEM. | SERVICE INFORMATION | TROUBLESHOOTING | eye rank | AIR QLEANER CASE CARBURETOR REMOVAL SERVICE INFORMATION =z Gasoline is exiremely flammable and ic explosive uni Work ne well ventilated area, Bo not exoke a Uf the engine must be nunning to da same work, make sure the area is well-ventilated. Never rin at may canse los of consciousness andi lend 10 dedi, The ethaust ca GENERAL © When a jezembling {uel system parts, note the locations of the ©- CARBURETOR DISASSEMBLY CARBURETOR ASSEMBLY ‘CARBURETOR INSTALLATION PILOT SCREW ADJUSTMENT ACCELERATOR PUMP The csrburetor float how! has # disin plug that can be loosened fo drain residust fe. caution Do mot ben a Pst co Nore resulting in hava starting oF poor ariveanity. SPECIFICATIONS Te ‘of cables, Damaged conirot cables il ni It the vehicles 1 be stored Tor mare that one month, drain the float bowl, Fuel eft in te flvet blow may couse clogyed ets epsea |] {Gil type: POSE F type: PDBBC 4 mmm (0.85 inh 4138 Gi ype: 4145 F type: #182 38 200 + 100 rin"! Iron) 2-6 mm (1/16—1/4 in) Ww Gil type 25.6 198. Replace them dung reassemntty 46 49 ane ana a6 certain conditions ark ina well rextleted area with the engine stopped low flares or sparks in the work area or where gasoline ts stored. the engine san enctosedt are,FUEL SYSTEM oo TORQUE VALUE Foal tank mouaclag belt Engne mourning 10 eam bolt 768 Engite bracket & mm bolt TOOLS special Pilot screw wrench o7008 common Fost level g2uge 074% TROUBLESHOOTING Engine eranks bur won't start No fuet in tank {Mo fuel c0 carburetor Engine ‘looded with Tuet + No spark 2t plug lignition system malfunction + Clogged air cleaner + Snakes air feaK + improper choke operation Improper thromtie operation Hard starting or stating after starting + lmpraner choke operation + gation matfuneson + Fauty corburetor + Fue! contaminates + Intakes ait aK Incorrect ide speed clearance (Section 3} Fough idle Ignition systern malfunction Incorrect idle speed Incorrect valve clearance (Section 3 Cytinge: compression coo low Fauity caroure Fuel contaminated Dirty air cleaner 1ONem (1 Okgim, TAI) (7.8 kg-m, 84 Feb 27 Nom (2.7 kg. 20 F16) Misfiring during aeccolaration Ignition aystem meliunetion Backfring Ignition system metfunetion Faulty carburator Poor performence (drivaabilty) and poor fol aconomy (Clogged fue! system Ignition system metfunetion Dirty air leaner Lean mixture Clogged fue! jeto Faulty float vaive 9 Hloat lovel Glegged tue! tank brosther Clogged fuel ateaner Restreted fuel line intake air laak Rich mixture Carburetor choke stuck clos aulty float vaivo Float level 190 high Dirty air cleanar 4-2FUEL SYSTEM FUEL TANK REMOVAL = Gasoline ts extremely flammable and is explosive under certo Canditians. Work in @ well ventilated arca vith the engine stopped. Do not smoke or allow flames or sparks in the work (1) FUEL TANK MOUNTING aout y Remove the seat and side fairings (page 15.2) ‘Turn the fual valve oft, and disconect the faa! tube ‘Romove the mounting bolt and the fuel tank Check that the fuel flows aut of the ful value Frey Hoy ricted, claan the fuel strainer INSTALLATION Iota the fusl tank with tha mounting bait Connact the fuel line + After assembling, make sure there are no fuel leaks. Oo net vertighten the fuel valve hock mut Reinstall the fairings and tha seat 10 Norn (1.0 kgm, 7 fe} 1) FUEL, VALVE 12) STRAINER SCREEN (5) FUEL VALVE . Lock NUT (3) O-RINGFUEL SYSTEM AIR CLEANER CASE (2) AIR CLEANER CASE MOUNTING HOTS REMOVAL, Remove the following wiseat and fuel tank (page 4-2). ~ air leaner case cover. — tir cleaner cose mourting bolts. Disconnect the toilight connector, starter relay switch and braather tuba frorn the air cloaner case, Remave the following: ‘erburetor Ipage 48). = exhaust pipe/muttior page 15-1) = tegulator/rectiier (page 16-6) — battery (page 16-4) ~ 0" Fender. ~ ir cleaner case. INSTALLATION Install the removed paris in the reverse order of removal (2) oaTTERY in) staRtTeR—— RELAY (7) BREA’ AIR CLEANER SUBE CASEFUEL SYSTEM. FUEL SYSTEM CARBURETOR REMOVAL ‘ase s extremely Plarumable and is explosive wnder cotain Conditions. Work ina well ventiloted area sth the engine stop- ped. Do uot smoke ov allow flames or sparks in the work area tr where gasoline is stared. Femove the Following seat and fuel tank ipage 4-3). — fear side cover end air cleaner coee cover ipage 15-2) Loosen the cerburetor drain scrow and drain the fuel into a Remove the ar cleaner case mounting bolts. Remove the upper engine bracket ang disconnect the throttie abies, Disconnect the choke cable and loosen the carburetor ingula- lor band sevews, then remove the carburetor from the left (1) BRACKET 4-5FUEL SYSTEM CARBURETOR DISASSEMBLY Remove the thrae serene ond the accelerator diaphragm Rernove the diaphragm spring eed dianhvagm Check the diaphragm for a tone deterioration Chook the rod for wear and trueness. Remave tha three screws and the float chamber Aemave the flest pin, float, hatte plate and float vane (2) FLOAT CHAMBER (1) DIAPHRAGMFUEL SYSTEM inspect the flaat valve seat for grooves ond nieke, Chock the operetion of the float valve, Remove the two ccrawa and the carburator tap cover. (1) cansuneron Tor cover Lg Remove the throttle tink attaching serow ond the throttle valve (SCREW Remaua tha pilot screw, main at holder and ela jt. Main Jet Houoer NOTE Do not iry ta ramos the Haat valve seat from tha carhure. tor body. + Batore romou 6 the pilot serew, record the numbar of turns 1 seate lightly Us this as a reference for installation. Romove the jet needle by pressing {Cout from tha thyattla valve sid care (3) MAIN JET Caan the jets with comoressed cit. Inspect the jets far maar or damage an replace if 47FUEL SYSTEM Aemove the two screws ancl the ser plate Inspect the throttie valve for wear or scratches, Inspect the jat needa for ame, Remove ihe mrottle siop screw ar cattle from the carb by removing the cover screws. ‘Blow open all carburetor body openings with compressed ai Zé (ier NEEDLE 4-8FUEL SYSTEM CARBURETOR ASSEMBLY (21 TOP CavER [7a ser Necoue ae (Ga. (5) THROTTLE VALVE (18) o-ntvG——_* (16) PLOT SCREW, (74) MAIN JET: (19) BAFFLE PLATE tin) FLOAT a CHAMBER 12) DRAIN SCREW (10) DIAPHRAGM COVER, Instoll the apring onto the sable and serew tho cable in tho ear ureter Instollo new O ring and cover, thon tighten the acraws cacurs (2) THROTTLE - stop schew 49FUEL SYSTEM Anatall the main jot jt holder and slow jot ‘CAUTION Handle alt jets with core, They can easily Be scored 0 veraiched, Install the pilot soraw and returt it 9 its original position as, noted curing cernaval Perform a pilot serew adjustment It a new pilot screw Is fy ‘taled (page 4-74). Instat the float valve, float, Haat pin and batt plate ‘With the float valve seated anc! the float atm just touching the valve, measure the fost lavel with the float level oauge 3s, shown, SPECIFICATION: 14 mm (0.55 in Toot Float level gage (97401—0010000 The fost cannot he adjusted Raplace the float assembly if the level is out of specification. Inetall the O-rings. Install the float chamber, aligning the averfiow tube on the chamber with the hale inthe batfle as shown _(2y stow Jer (3) JeT "HOLDER @) Man “ET 1), Se RAT Pn 1) FLOAT VALVE! (1) ovERFLOw (2) 0-FINGS 4-10FUEL SYSTEM Tighten the Mloas chamber screws. Iostall the acselerator diaphrage ond dust boot Install the spring and cover. Tighten the verawe and stamp 98 shown 4-11 it) ust BoorFUEL SYSTEM il the spring 98 shown, 1) SPRING Pe 3 ay Install the jet naedle into the throttle valve (1) THROTTLE VALVE Instal the spring on the set plate, and install the set state in te JET NEEDLE 4 3) ser Lae wk 4S 4 (a) spain. Install and tighten the serews. Instal the tink arm to the theorte valve and tighten the screw. 4-12FUEL SYSTEM taspect the linkage operetion: Tas THROTTE ORUM — Open the throttle aightly by prosting on the throttlo drum. Then release the throtte — Make sure that there ie n@ deag. lastalla new gasket on the top cover, Tighton the screws Yaar (1) AiR VENT TUBE Install the carburetor tubes. & 2) DRAIN Use > (ah Fur. TUBE 4-13FUEL SYSTEM FUEL SYSTEM CARBURETOR INSTALLATION Inctatotion ie eccentilly the raverse order ot remavat Install the carburator hy aligning its intake pipe boss with the fnauletor groove + Route the thrattie and choke cables properly (page through 1:12), Instal the upper engine beackat and tighten the bolts TORQUE: “10 mm bolt: 76 Nem (7.6 kg-m, 54 fttb) 1 min bok: 27 Nery (2.5 kgm, 20 feb) orform the following inspections and adjustments. + Throttle opsration ipage 3.4), + Corouretor choke (page 3:5) + Cerouretoridte spond (page 3-9) PILOT SCREW ADJUSTMENT Nove + The pilot screw is factory preset, Adjustment is cot pecessary unless the carburetor is avertiauted ar anew pilot Sserew 18 instal: caurion + Damage 10 the pilot screw seat will cur if the pilot serew is lighened agains te seat Turn the pilot screw clockwise until it pate lightly and back it cut 1-1/2, Gil type 2-518 ture. This fs or initiot setting prior to tho fiea! pilot screw adjustment TOOL: Pilot screw wrench 07908 4730001 \Waten the engine up to operating temaoroture Stop the engine and connect 9 tachometer a AES WRENCH Start the engine and adjust the idle speed with the thvotte IDLE SPEED: 1,300:* 100 min-* rpm) Turn the pil screw clackivise until you heat tbe angine sss dl, then tuen counterclocknise uetil the ngine again misses oF decreases in spe Center the pila: screw exactly between) these two extreme Idle speed chang fier adjusting the pilot sciewr, reaivst the thrattle stop screw. 4-14FUEL SYSTEM ACCELERATOR PUMP r CAUTION +The accelerator purmp-adjuesiment mut is factory pre-set Sa gas tno 0 oa win eons | SEE IDLE SPEED: 1.300» 100 rin pm) FREE PLAY: 2—6 awn (1/6—1/4 in} 4-15