Repair Procedure

Figure 2:

1. Remove the heat protector (Figure 2).

2. Visually inspect the back side of the heat protector for signs of gas leakage like black sooty carbon deposits.

3. If you see any sign of gas leakage from the exhaust manifold (black sooty carbon deposit), replace the exhaust manifold as described in the service manual.

NOTE: It is not necessary to replace the exhaust manifold even though the manifold has cracks if there is no sign of exhaust gas leakage on the back side of the heat protector.

4. Reinstall the heat protector.


5. Clean the outside of the carburetor using carburetor spray cleaner. Check the choke valve for smooth operation.

Figure 3:

6. Using carburetor spray cleaner, clean the choke shaft and the Secondary Main Air Jet (Figure 3).

Figure 4:

7. Verify that the carburetor throttle plate is closed. Remove and discard the Primary Main Air Jet. Replace the Primary Main Air Jet with the replacement air jet that is contained in the parts kit (Figure 4).
NOTE: When removing or replacing the Primary Main Air Jet, use a screwdriver that is an exact fit for the slot and work carefully to prevent damage.

CAUTION: Do not drop the Primary Main Air Jet into the carburetor throat!

Figure 5:

8. Turn the Fast Idle Adjustment Screw 3/8 turn clockwise (Figure 5).

NOTE: The Fast Idle Adjustment Screw has a slot for screwdriver engagement. It can be identified by yellow paint that was applied during manufacture.

Figure 6:

BEFORE INSTALLING THE CHOKE SHIM READ THROUGH THE FOLLOWING 3 PAGES.


9. Install the choke shim that was included in the emission parts kit as described in Figures 6, 7, 8, 9, 10, and 11.


Shown in Figure 6 is a basic outline view of the choke mechanism.

NOTE: The area between the choke adjustment screw and the plunger is behind the choke linkage and is hidden from view.

Figure 7:

Figure 8:

NOTE:

A mirror must be placed beside the carburetor next to the thottle lever. This will allow you to see the area that the choke shim must be installed in.

Figure 9:

9A. Using the fast idle release driver special tool, insert the tool between the thermo wax element housing and the choke linkage (Figure 9).

Figure 10:

9B. Spread the choke linkages to create a gap between the choke adjustment screw and the plunger of the thermo wax element. Make sure not to interfere with the throttle lever or other linkages. With the linkages spread, install the cap portion of the choke shim onto the threaded end of the choke adjustment screw. The cap portion of the shim should be inserted between the plunger and the choke adjustment screw (Figure 10).

Figure 11:

9C. Remove the fast idle release driver. Carefully twist the handle of the choke shim and allow the handle to break off the cap portion. Using a flashlight and mirror visually verify that the shim is still in place and fully seated on the choke adjustment screw (Figure 11).