ANUAL SERVICE M

CARBURETOR ASSEMBLY

Install the throttle position sensor by aligning the tabs of the throttle position sensor with the flat side of the shaft as shown.

05, 06:

Tighten the torx screw to the specified torque. TORQUE: 3.4 N m (0.3 kgf-m, 2.5 Ibf-ft)

After 06:

Tighten the bolt to the specified torque.

TORQUE: 3.4 N m (0.3 kgf m, 2.5 Ibf-ft)

• The throttle position sensor is factory pre-set and no adjustment is necessary unless the throttle position sensor is replaced.

• For sensor inspection (page 18-9) and replace­ment (page 6-26).

Install the O-ring, washer, spring and pilot screw.

Perform pilot screw adjustment if a new pilot screw is installed (page 6-27).

• Install the pilot screw and return it to its original position as noted during removal.

Install the slow jet, starter jet, baffle plate, needle jet and main jet.

TORQUE:

Slow jet: 1.5 N-m (0.2 kgf-m, 1.1 Ibf-ft)

Starter jet: 1.5 N-m (0.2 kgf-m, 1.1 Ibf ft)

Needle jet: 1.8 N m (0.2 kgf m, 1.3 Ibf ft)

Main jet: 1.5 N-m (0.2 kgf-m, 1.1 Ibf-ft)

Install and tighten the slow air jet to the specified torque.

TORQUE: 0.9 N m (0.1 kgf m, 0.7 Ibf-ft)

Install the float valve, float and float pin.

Set the float level gauge so it is perpendicular to the float chamber face and in-line with the main jet.

Set the carburetor so the float valve just contacts the float arm lip. Make sure the float valve tip is securely in contact with the valve seat.

Make sure the float is level with the float level gauge.

TOOL:

Carburetor float level gauge 07401-0010000 FLOAT LEVEL: 8.0 mm (0.31 in)

If the float level is out of specification, adjust it by bending the lip.

Install the push rod while holding the push rod link lever.

Install the acc. pump bypass into the float chamber and tighten it to the specified torque.

TORQUE: 0.3 N m (0.03 kgf-m, 0.2 lbf-ft)

Install a new O-ring to the float chamber. Install the float chamber to the carburetor.

Install the hose guides and float chamber screws. Tighten the screws to the specified torque.

TORQUE: 2.1 N m (0.2 kgf m, 1.5 Ibf ft)

Install the throttle stop screw stay and tighten the screw securely.

Install a new D-ring with it flat side facing forward the accelerator pump cover.

Install the diaphragm, spring, new О-rings and accelerator pump cover.

Install and tighten the screws to the specified torque.

TORQUE: 2.1 N m (0.2 kgf m, 1.5 Ibfft)

Install the choke knob and tighten the lock nut to the specified torque.

TORQUE: 2.1 N m (0.2 kgf m, 1.5 Ibf ft)

Assemble the roller and throttle valve plate on the throttle valve.

• Install the throttle valve plate with the seal side facing toward the throttle valve.

Install the throttle valve assembly into the carbure­tor with the valve plate facing towards the engine side.

• Make sure the throttle valve moves smoothly.

Align the holes in the throttle shaft arm and throttle shaft.

Apply locking agent to the screw threads.

Install and tighten the throttle shaft screw to the specified torque.

TORQUE: 2.1 Nm (0.2 kgf m, 1.5 Ibf ft)

Apply locking agent to the torx screw threads.

Install and tighten the throttle shaft torx screw to the specified torque.

TORQUE: 2.1 N m (0.2 kgf m, 1.5 lbf-ft)

Install the jet needle clip to the jet needle.

STANDARD CLIP POSITION:

2nd position from the top

Install the jet needle and needle holder into the throttle valve.

Tighten the needle holder to the specified torque. TORQUE: 2.1 N m (0.2 kgf m, 1.5 Ibf ft)

Install the jet needle/holder assembly into the throt­tle valve.

Tighten the jet needle/holder assembly to the speci­fied torque.

TORQUE: 2.1 N-m (0.2 kgf m, 1.5 Ibf ft)

Install a new O-ring and top cover.

Install the clamp and bolts.

Tighten the bolts to the specified torque.

TORQUE: 2.1 N-m (0.2 kgf-m, 1.5 Ibf-ft)

Clamp the throttle position sensor wire as shown.

Connect the overflow hose, air vent hoses and fuel hose.

THROTTLE DRUM