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:

FUEL SYSTEM
Page
6-2
I

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a"
- -'-- - iWittr High speed valve)
CI\RBURETOR
I

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CARBURETOR
-
(Wittrout High Speed Valve) ............ "" 6'24
 FUEL SYSTEM - Fuel PumP

FUEL PUMP
COMPONENTS '*

Fuel Pump
Gasket
Inrula tor

]NSPECTION (AIRTIGHT TESTI

- Proctution -
Before performlng ths fotfowing checkr on tfie
fuct pump: '*
1. Run fonro fucl throudr the pump to inrurc
thrt tfrr chcck yrfyg rcali tfghtfy (r dry
chsck YrfYs mry not rosl proporfyl.
2. Wltholtt blocklng off rny pipor, opontr tlrr
, pump frvsr ud ohock thr fmount of forcc
neorslrry for opcntlon rndrthe rmqrnt of
' lrm plry. Thir ram. .mqfnt of force rhould
, f. urod In thi chcckr.

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FUEL SYSTEM - Fue! :Pump 6-3
l,
',I t Fig. 6-3
I
l. Check inlet valve
Block off the outfet pipes with yotfr linger
And Check that there is an increase irt lcryer
arm play and that the lenrer aim moves freely
(lost motion - oo reactiort forcel.

I
Fig. 64
2. Check q.rtlet valve
Block off the infet pipe with your finger an!
check that the arm locks (does not operate
with sarng arnq.lnt of f orce used in the
precheck above).

- Nota -
Nrucr ule moro force than thrt urcd in the
pr$hrck 'Thlr rpplio to checkr 3 rnd 4 rtrol,

Fig. 6-5
r a ar--
3. Check diaphragm
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I Block off the infet and outbt pipes and

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check that lhe pump arm locks.
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- Notg
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lf ;ll ttrru of tterc checkt !r! not !t spocifiod,
i:
I thr crulklng bcallngl of thr body"-rnd uppcr
cesing ir drfsctive.

.,'g. 6-6
Check oil seal
Block otf ths vent hofe with your finger and
check that the pump arm locks.

*
:*

,*
6-4 F UE L SYSTE M r* (,at b'uretoT (With High Spced Vrlvrl
.il
CARBURETOR (With High SPeed Valve)
CARBURETOR CIRCUIT 'il
Fig. 6.7

2 t ,+ 5 6 7 I 10 11

lr 3-------?--:=::=h'i
rl
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rl a

I ?- ------1.E333----------i,-i.i=--=
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ii
rf
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ii=+
L5l
it

.lrf-
a---

,{ Fr ==='ij
/ I L--;L,
- - -r--
---J
-.;--
-:-ir---J
-- J. --l---
--l----
- \'-;

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2 13 15 16 17 18 19 20 22 23
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a

I. Power Pirton 3, Flort

|
2. Slow Jrt 14. Poyvrr Vrfvr
3. Solenoid Vclvc 16. Primrry Mrln &r
4. Chokc Brcrkcr | 6f Powrr Jrr
5. Primry Main Norzts Id ldb Mixrurt Adjurting gcrcw
5. Cho ke Valva t 8. Fivot Plug
7. Pump Jer | 9. Sf ow Port
8. Secondary Msin Nozzf o 20, ldfe Porr
O 'Punrp Discharge Weiglrt 21 . Primory Throttfo Vcfvs
I O, Purrrp Plungcf 22, Socondary Throtth Volve
I l. Therrnostst Valvs 23. High Speed Valvc
I 2. Need le Va lve . r 24, Secondary Mrin Jct

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*
DISASSEMBLY
Air Horn
* rts in the numerical ()rder
shown in the f igure.

USE SST [09860.1 101 1 ] FOR CAREUR ETOR SERVICING

Genciel 4K AIT

l. Horc & Thermorul i/rivf

2, Pump Arm Sot Scraw
3. Pump Connocting Link
4. Fart ldlo Connecting L, rk
5, ' Throttlc Poritioncr
6.' Choke Breoker
7. Air Horn

*
 s*6 FUEL $Y$.i Ifvi,*,{^li'r
+|,| 'F.k{irri.irEtur
r}'..rrstor ty'dttrl
t\^lith rlt{in
High bpuuu
$prud V;rfvs}
vitlvg, .
q{ r *.+ftl+,ria**ri.r!e.:.,:+t+*ri*lfr.,+rfr

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?. Disassemble the parr in the numericar order
?

shown in the figure. *

Fig. 6-9

1'l 1*t 15
I t *-.'-*."r..-*an
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Fig, 6'l I f
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ES 0@
oe o o. 9 Fig. 6.10
10 '-"-*-ie+iq*

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@
s
12. Velvo $ot $crcw
13. Cho ks Vrlvr
14. Chokr Vrlvr Shsf t
IS. Chokr Vrlw fiefirf Sine

#+#ff'f 'rl* |

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6.1 I
,
F ig,
F
To rennovs choks varvs, file off the end of the set
SCrgws.

- Noto -
Do thil only if it it nscsrsary to ropfacs tho
I
choke yalvo or rhaft.
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FUE L SYSTEM - Ctrburf tor (lVittr High Spdsd Valvel 6-7

* I

Body
t Disssmbfe rhe parts
shourrt in the figrrre;
in the numericaf order

; tlt.': .,1
{r'l!','- .,
F ig, 6.13

Flg. 6.13

FI

t ta

l, Pr'lmp Oirchrrg0 Wright & Errf Erll 0.

2. Primp Ormplng Sprlng & Strl B.lf 7,
3. $iow Jet a
4. Pawgr \rafvo & Povrpr Jrt 9,
5. .f{iryop, Moin Jst fo

Fig,6-13

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,*
f ig. 6'14
Using twoezsrc. take out the check ball retainer
A from thg bottom of pump cylinder. turn the {F
carburetor upsid dOwn and drop out the steel
bafl B.

F ig, 6- l5
Remore the slow iet with SST.
ssT [0e86G1 101 I I

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Rornwbttre powor vatvo with SST.
ssr l0ge601tor 1l
i,,,
;

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{**tt$f($t*#aaft}*'*ritir..rt rri rrii*ip,.-***.**,-.-*".*i**.*.r*-

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 ft

FUEL SYSTEM - Carburetor (V"ith Hi'gh Speed Valve)

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Flange .
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order
* It Disassemble the Parts, in tlne numerical
shown in the figure'

Fig.S'18

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'lli
- Carburtor (lVith High Sperd Vrlurl
.*
INSPECTION Fa

- Ptacautlon - .#
1. Brfon frupocdng thr glfi, wr$ thm
tlroroughlV fn grrollnr, ,tfdng comprrr$d
dr, blow dl dlrt ud othrr fonlgn mNttrt
frgm thl lru rnd dnrlfrr prtt, rd fronr 9ilo
furl p+fgpurdrprrunr tn rhr body.
7i Nrnl drrn th.Fg or odflee w|dr wfn or r
drlll. Thh ceuH rdrrf thi Wrnfng! urd
n4rft ln rxeerlrr fud cgn;qnrpgo&

' a.

Fig. g'22
Insect,the fofforlng parts rnd reglacs any part

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i FUEL SYSTEM - Crrburetor (Wim High Speed Vatvs) 6-fr
* .

!-

4. Strainer: Rust, breaks.

* 5. Needle valvs srrf*o.
6. Ndle valve seat.
7, Power plston: Scratchc, excessive rnnar.
Pounr piston spring broken or deformed.

. i.

8. choke vafve: Dsformatign. choke straft

' ,; iftror;I, bont, or not fitting propedy in the
housing

srrfffi,
;

Venturi: D.amagn of clogginei

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6*12 FUE L $ YqT'E M - Carfrurelor (IVitlr l'lrglr Speed Val '8)

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F ig. 6'? I l-l ? Jets: Dam@ contacting surface, damaged
llt?51 -' threads or cfogging and screwdriver sfots. '#
*tr-
lu l !
Power valvs: Faufty opening and closing
---&, __
--E-
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action, damagnd contacting surfass ild
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threads or clogging.
tr_- -r
-

lii -
E

.--.-
I I I-- -

-.:--
';

&[

#
tr- _r
-- T

#...
r-h
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F ig, S'30
,.,.
5. Acceleration pump
Pump damping spring: Deforrnation, rust
Pump check ball: frmaged, ruEted. '"
F8 Pump pfunger: Wear at sliding surfacs,
H:I
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>rb
deformd or damagsd leathcr,
t3

Fig.6-3I ta

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,
Fig. 6.3e
Throttle raafves: Wear or dgformation in
valvst. Wear. bending, twisting or faulty
movement inside houslng of shaft.

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 !

FLIEL SYSTEM - Carbur3tor lWitn High Speed Volvel

* i
F ig, 0.33
t. l:l 3. ldfe mixture adiusting screw: Danlage
ji-r
I I lrltl
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.^^ara.al ti^ ar rh;aarlc
arl I
'tlF a
--
lvt

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Fig,6-34
Throttle Poritioner & Choke Breaker
Conn*t a hms to the diaphrEgm and suck.
The diaphragm should more. lf not, replace it.

Solenoid Vatve
Chrck operation of solenoid raalvc.
Connect wlring to ttp battery p6sitive terminal
t and grourd ttn bo$. Tho nlgosfe vslv shup fn
pulled in,

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6- 14 FUEL SYST E Ml * Carbureror (Wirh Higtr Spoed Vitvel

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ll ASSEMBLY i.

$
Flangn
Assemble tha: parts ln the numerigal order shown
t
in the figure.

Fig.6-36

Bof t
Vrcuum Purgr Boft
fdfr Mlrturo Adfurring Scrtw

F ig, 6-3 7
Assemble the vacuum passagp boft in the pocition
shown in the fignlre.
l?*

- NotO -
Uro r new gnrkot
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Tighten the bcfts with SST.
ssT [0e8sr lot 1l

;tilffiffiai;
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FUEL SYSTEM - Cerburetor-(Wi rh High Speed Valve) rj-r5

*
, 1'
It ii'il Body
i i'f
{r, .
Assemble the parts in thg numerical order shown
: in the figure.

Fig.6-39

8riig.6{2
643

tl
56

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3Fis.o{l

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lf ? '
-\==-- o
2 Fig,o4o
L--,

F::F ''.
I F6.640

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l. Prirnry Moln Jrt 0, $rcondrv Snrrf f Vrnturf

2. Sccondary Mrln Jrt 7, Pump Drmpine Spring &, $teet Satt
3. Poweg Vrfvr & Porrr Jrt 8. Pump Dirchrrgc Wright & Stsel Balf
4. Slow Jrt 9. Thrrmorutic Vafw Covrr
5. Primury Smaf l Venturi f0. Sofrnoid Velvc
t.

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6*16 F UE L SYFTEM - Carbureter (!i'ith l'{iglr Speed Valve}

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Fig.6-40
Install the main iets with new gaskets.
Primary iet Bras *
SecondarY iet
- Chrome

-Jg
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F iS. 6-4 1

Install the following parts as shown in the figure.

, Slow jet
Power vafve

Fig. 642

wEItrf;i - Noto - *
There aru two rizer of balls.
Lugcr bsll: For pump outlet.
Smrlhr bslf : For pump inlot.

.,:
F i0" 6-43
f--:' -' '
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close off the discharge weight with your finger
I
I
and put a smafl arnount of fuer into the float
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chamber. Push the acceferator pump and check
i
to see that fuel spurts from the nozzfe.

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 FUEL SYSTEM -Cerburetor (Wi th llrgh Speed Valve) b'l 7

*
Air Horn ' r"'r'

# Asemble the parts in the numericaf order sh'rwn

in the f igure.

F i11. 6-4 4

t.--
j g

Fig. 647

FsTt

5 -, ,,., *,
a
O
Fig,6-4{i o

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14:
**
i0. 6-5 ?

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10
1?--
13 -*-

l. Cnoke Valvs Rotief Spring 9. Air Hor:n

2, ( tsioke Volvg Shrf t I O. Cho kr Brcrkrr
3. Cnoko Valvd If. Throttfr Poritionar
4. I /alvs
Se t Screw 12, Fut, ldh Connrtlng Llnk'
5. P.;wer Pirton & Spring | 3. r Pump Connccting Link
6. Valw Subssembly
frleedle t{. Pump Arm Srt Scrcw
7, Fio{t & Ffort Pirpt Pin | 5. Horc & Thcrmosutic Vofve
B, Pump Pfungr

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fi* l8 ttUtL fiYtiTfi[$ * HrburntsT t\$ith tiigh $otsE Vdrri

fri* S{5
Install the choke valve, and then peen the end of
scrgws i !
,t

Fis i 46

illfl,if,+r
Instalf tho valve seat, needle valve, spring and

m push pin in order.

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FiS.6-48
fr'-'" Adjust the position of the floar.
l. Allow the f loat to hang by its own weighl.
2. Check the c*aranr:e between the float tipr
and air horn with SST.
ssr [og24soool4l
Rairod porition cf cara nce :

2K, 3K tcrior 6.0 mm

I
(0.236 in, )
4K,5K Scriu 7.5 mn.
(0.295 in.l

?
 FUE L SYSTEM - CarburEtor (Witn High Speed Valve) 6-19
*
Fig. S4g

* - Noto -
'*-*'-Thir mcrurcment b- elwayr mado without a
gukrt on thr air horn.

3. Adjust ths clearance by bending at poirrr n

of the float as shown in tho figure.
.tl

F ig. 6-50
Adiust lowrreO poeition of the float.
1 . Lift tho float and check the clearance
bsturyp-n the needls vdw plunger and floar
. f ip with SST.
ssr [0924s000201
rsrurtd pgrldoli clornecr:
I

eK,3K Srr.ir O.g fnm

(0.035 in.)
4K,5K Srrlc 0.0 mm
(0.024 In.l

Fig.6-51
Adiust, th cleerance W bending tab B of the
f loat as shq,Yn in the figure.

t,
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eK, sK.C & 3K.H 4K & 4K.C

' .:

Fl* 6-52
AsiGmbfs tho body an d air horn o/er a new
ggsket.

- Crutlon -
1. Ttkl erre not to &mlt drr Ftmp pfungrr
flltfrr.
2. AnmHr tfrr rir horn wlttr tht pump ict
poritlonrd corrcctly.
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 6-2A rr
.FUE L, SYSTEM
| ! r F ,! ,r
- Carburetqr (with Hioh $pccd Valvrl
. F I | | ! ! | tr - I

' ' " :li ':

o
( Fig.6-53 ADJUSTMENT
Use SST to make adiustmsnts. tb
ssr [09240'oool4l
los24s00020l

Fi* 6.54
Primary throttle valve opening

EI (t ) Fuf ly open the primary throttle vafve.

Ql Check the primary throttle valve open.
ing angle.
Oprnlng rnCf : 90o

Figr 6.55
(3) Adjust by bending the throttfe lwer
$topper.

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FiS,6-U6 i

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Secondary throttle valve opening ;
'fl{
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( ) Fully opn the primery throttle vaf ve.
t .f
l2l ft*! the scondary throttle vaf ve I

qpe.llng angle. s
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Opcning rngfr: gqo ,i
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FUE L SYSTEM - carburetor {wirh Hish speed Vaf ve} 6-21
*
Fig. 6.57
(31 Adju$t,by bending the throttle shaft
* link 1.

F ig. 6-58
Fast idle
(l l Fully close the choke vafve by turning
the choke shaft lever.

QI Ar this tima, chck the primary throt.

tle valve oponing engle with SST.
SST [092t1009l4l
* Frrt ldh rqh: 28o

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F il, 6.60
{3) , Adiust by turning the fast idle adjust-
i

ing scrgrr A.

- Crud(Dn -
8r sn $ln lr: cflrRncr rmrdnfng rf,Or rdlurt
mrnt

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g*22 FUEL SYSTEM - Carburetor (Witn Hieh $pesd Vrlvcl

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FE. S'61
1

"

4, f dle mixture adiusting scrsw

(,1,1 ' Tighten th idle mixture adjusting *

$crow to fully cfoeod'position and then
unscrew it as foffows with SST (ECE)
or ascrewdriver (Generaf destinations).
ssr [09243-ooo2ol
Approx. 3 turnr

\ - Clution - O
Trkr crrr not to rcrm in too tightfy rnd s-.nag3
\ thr rcrc* tlp, :

Fig. 6?
(2) Install the new limiter cap on the idle
mixture adjusting screw. (sweden
onlyl

FIT'6"E3
Choke breaker
(l l Fully cloco the choks valve.
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Fi* 0{{
{?} Appfy vecuum to the choke breaker
and check the choke vafve clearance.
Chokr bnrkrr cllrnncf s
2.22-2.32 mm
10.0874 - O.Ogl3 In.l

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 FUEL SYSTEM - Carburetor (Excrpt KP61 Series & KM Seriesl 6*23

*
FiS. S5
(3) Adjust by bending the connectipg link
il A.

St.
r ls o-oo
^
t^ta

6. Acceferating pump
Adjust the pump stroke by bending part A
as shown in the figure.
Acolmtine pump rtrokr:
2K tKHtdl 3.00 mm
(0.1 181 in.)
2K (KPS0}, 4K,5K $rrhr
o 4.85 mm
(0,19O9 in,l
t

3K Srrbr 3r5 mm
10.1280 in.l

- Notl -
Aftrr rdjurtmcnt, br rurr to dreck tha linkrgn to
n t{rrt it opcrltrl rmoothly.

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 6r?4 FUf; L $V$Tff!,l T Carbursror'.,{l,Vithour Hlgh Spsgd,Vrive}

*
CAR B U RETOR (Without High Speed Valve) :

cAnBuREtpR clncufr F
FiS. 67
[*-._-
T

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To BVSV
(USA &-Canadal
4ii rl
5
fl
'll

ii ----rL
,-- --.1 -*---
r-- -! .--a

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.r-Drea!r;
rerFttata.at-Irr
-.--
-aD--r

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+ n
ii'--':::::
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aFal.-- -

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15 1S 1? re r{i 20 21 22 23 ?4

l, Pey.'cr Piston
13. F toot
?. Slqrw *,t
!4. Powr Volvt
3. $oleno ic! VEilve
r5. Primlry Mrin &r
rl fhoke Ereaker or Choke Opener t6. Power Jet
5 Pr,ntary lr,tgrn FJorllr: \
17. ldte Mixturc Adjuriing Screw
6 Ctrgl'.t V,live
t8. Plug River
7 Punrg Jet
rg. Sloru P-orr
I Sec0rrtJ$r-r fularn Norrf r
a 20. ldl6 Por r
Pu rTrp O 6cliprge Wergh t 21. Primary Throtrte Vafve
l0 l'r.,tnp FlunUef
2?. Secondary Throttfe
II Ttrurmurt$tic VElre Vaf ve
23. Secondrrv Thrortle Vatve Diaphrsgm
l'l lJrrtilp Vatvs
?4. Secondarv Main Jer i
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ft-':il{ttl.Fnrrerq,,h,. , *

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 \*

FUEL SYSTEM - Csrburfror (Without Htgh Spocd Vatval 'i 0-26

*
DISASSEMBLY !t-

Air Horn
l. Disassemble the parts in the numerical order
shown in the figlre.

F ig. 6.68
t----,
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usE [09860.1101 1I FOR CARBURETOR SERVICING
\

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! |, Pump Arm $t Scrar
l 2- Pucrp Connrctine Unk
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3. Thronb Ferftionrr
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l, Hort t Thrrmootrric Vrtvr
6. Brck Spring
6. Frrt ldr Crm Connrcting Unk
7. Ak Horn

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 :;

,
0t26 FUHL $YSTEM - Carburetor (Without High Speed Valvel
fr
2. Disassemble the parts in the numericaf order
shown in the f igure. *
Fif. F6g

I / lirrrg.e'/l

*>a io
nf'
E
'r r ''5' @ ft- 9 Fig, o.7o

fr
10 o
11
8. Float & Ftoat Pivor Pin 13. Chokr Brorker & Connecting Link
9. Nesdls Valvs Subassembly 14. Chokt Opqner & Connecting Link
10. PumF Plunger I 5. Chokc Valve
I l. Pornmr Pirton & funng 16. Choke Vatve Shrft & Spring
I ?. Fast ldls Com Connecring Link

Fth s?0
Remore the needle valve set with SST.
ssT l0986er 10r rI

*
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To remove the choke valve, file off the end of

the set screws.

- Noto -
Do thir onfy if it i; necersary to replace choke
valvc or rhaft. -=

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 *

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T-
;

FUE L SYSTEM - carburetor (without High Speed Vatve) 6*27

{l
+t
.r! Body
I
(lr Disassembfe the grartS in the ntrrnerical orcler
0 shovvn ilr the f igri
'

F ig. 6-7 2

F ig. 6.73
2 Fig..6.24

| 3 rig. 6.7s ,r
ll 4Fis.6-26 I
ll?l Iltr
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5 Fig. 6,77

il 6 rig. 6.tl
10
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f---;-sf?'r,\-
ri vt\\r Ii

i2iw' t\\\J7t I

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!

1. Pump Discharge Woigtrt & Steel Eatl 7, P irnry $mrtf Vrnturi

2. Pump Damping Spring & Stecf Ball 8. Sccondrry Srnrf f Vrnturi
3. Slow Jet 9. Falief $pring
4. Power Valve & Ponnr Jct 10. Sccondary Throttlo Vrlve Dirphrugm
5. Primary Main Jet It, Solsnoid Vatvc !

6. Secondary Main Jst

F ig. 6-73'
Tur.n:the cgrburetor upslde down, and rernove
the pump discharge weight A and steel ball 8.

- Clutlon -
Ure esro not to lorc thc rtocl ball.
*

t
 r}

T
*
!

FUEL EYSTEM 1 C9r!q1e-1oj h{lthbut Hlsh 6peed Velvel

b-2S

Using tweezer5, take OUt the cl'rcck tlall

r{-)lainer
b pump cyli6der. Turn the'
A from the bottom of
carburetor upside down and drop ou t the steei
ball B.

Rerrrove the slow jet with SSI'.

ssr t09860-1 101 I l

s
*

L
F ig. 6'76
f-l Remove the power valve with SS I'
sLs'
E#ffi t

{.
I r'+
ll
| ssr toegoo'1 I ot 1I

SST # e
-

tm Bef ore removin:g the prinrary Passage Plr-t$, looscri

the throttle lever set nut Ebout 4 tttrns
Remove tlre primary and sec:ondarY trrairt lets anC
gaskets witlr SST
ssr [09s60,1 101 I ]
* 6-29
FUEL dYsrEM - Carburetor (Withotrt H igh Speecl Va lve )

t Flange
Disassemble tlre L\ilr 1s in tlrq; tltJf'l'lil'f lt'.ll ()r tlt-::r

slrown in the f ic;trrc.

F ig. 6-78

ld!e Limitor Cap

r---rl
ioi
L--..J

3-
Fig.6-79
L
2,
ldle Mixture Adiusting Sc''ew
Bolt
t.
I

I 3. Vacuutn Pussage 'bolt

I

I
I
l--;-.-

F is. 6.79
RerncMe the tlvo boits with ssT.
ssr t0986$ 1,1 01 1 l

Fig, 6'80 INSPECTION

, -- PrecSution -
SEE t. Beforo ingpecting the p8rtt, warh thsrn
CARBURETOR thoroushf y in gsoling. uling colnprsgred
air, bloW rlf dirt end othsr foreign mffter
(EXCEPT KP61 SE R I ES & KM2O SE R I ES} from,the ie6.and rimllar part, rnd from the
fuel Panagpr ind aperturd ln the bocfy'
INSPECTION
2. Ntysr clean thi Jotr or orificsr with wirs or E
SECTION drill. Ttrli coufd rnlargs drs oponingl and
rerutt in cxcersivs fuel conlumption'
F ig. 6'2? to 6'35
I
,
 *
FUE L sYSTEM * Carburetor (without High,sPutd YIY:I

t
ASSEMB LY
Flange
shown
Assemble the Parts in the numerical order
in tlre figure.

F ig. 6'8 1

t*- t
I
t--

l. Bolt
2. Vacuum Posrage Bolt
3, ldle Mlxture Adiusting Screw
I

L __

ig. S'8 position

Assemble the vacuum passage bolt in the
F 2
f-l
Itf I
I

ll
\ .a.-l

shown in the figure. *

- NotG - *
i new gnrket
Ytt

Fig. 6'83
Tighten the bolts with SST.
ssr to986o-1 1ol I I
 ,.7
!

*
FUEL SYSTEM - Carburetor (Wi out High Speed Valve) 6-3r
f
Body rl

Assemble the parts in the t'lumerical or cJt'r :il'l,r\vri

a . a.

rn the ttgure.
F ig. 6-84
r'" - -.-=---^ -J_
10 F ig. 6.88 el

6-99 r.

1 1 Fis. G.Bs n
| 6 ris. 6.81 "
ll7ris.6:d?? ,

:lal i I

r=?
'-1
I
I
lil
!' g * t
I i
;^.-fi\d
I
I
t lR--j
4 6.86

ffisris6.s6

I
*
t. Secondary Throttlc Valve Diaphragm 7. Powrr Valv}&,.Porvsr 'Jet
2. Relief Soring 8. Primary Small Venturi
3. Solenoid Valva 9. Secondary Smrlf Vrnturl
4. Primary Main Jet lO. Pump Dirchrrgc Weight & Stecf Batl
5. Secondary Main Jct I l. Pump Drmping Spring & Stcet Bef t
6. Slow Jet

F ig. 6-85
f nstall the diaphragm rod A and washer onto

the diaphragm lever and f ock with a snap ring B.

I I
 *
s* 32 FUE L sysrEM - carburetor (without High speed_y1lve)
*
F ig. 6'8S
r_|lnsta||themainietswithnewgaskets.
l+f I nrimary iet Brass
l-J secondary iet
- - chrome
t'

l'

.tF
I

o
s

F ig. 6'8 7
shown in ttre f igure'
f,E Install the following parts as
-i
Slow iet
ffii*":t Power valve
Fi''
I

t s
-5-fi|ces-
Fln#ry -'
+l# ?
fi
tl
ill
,

Ez:-

-i
Fig. 6-89
Install the pun1p inlet ball, pump outlet bal I and
weight. *
l.
t
-Noto- f i *
Thsrs srs two rizer pf ballr.
Largor balf : I For PumP outl6t
Smaller ball: ' For PumP inlet

F ig. 6.89
I
r-* Closeoff the discharge weight with your finger 1
and put a small amount of fuel into the float I

chamber. Push the accelera'tgr pump and check I

to see that fuel spurts f rom the noz zle.

(
I

!
 *
FUEL SYSTEM - Carburetor {witiout High Speed Valve} 6* 33

t i

Air Horn
Assemble the t)arls irr the nutner ical rrrrlcr sllirrvrr
in the figure.

F ig. 6-90

r-----
| -ft\-- n I U
n$n\.%
I
1

@
e -Zrig.o.gl

9 rie. 6;9?
6:95

'r'

6
o
il
t
l. Choke Valvo Shaft & Spring 6. Powrr Pilton & Spring
2 , Cho ke Valvs 7. Pump Plungor
3. Choke Breaker & Connecting Link 8. Neodl,e Valve Subarsembly
1, Choke Opener & Connecting Link 9. Float & Float Pivot Pin
5. Fast ldla Cam Connecting Link

Fig. 6-91 a

1-I Install the choke valv, and then peen the end of
I

IY
---l

rl A L'

scrgws.
,-- s
?

$
e

: :

,,
t'
t.'
I I
t:
!
!'

F
 *
6-34 FUE L SYSTEM - Carburetor (Without High Speed Valvel

*
I
r * 6-9 ?
Fie
Adiust the raised position of the f loat.
l. Allow the float to hang by its own weight.
I
I

I
I
2. Check the clearance between the float tip
I
I
and air horn with SST.
I
I
ssT toe24soool 41
I

I
Raised porition clearancei ,
I
I
I
6.5 - 7.5 mm (0,256 - 0.295 in.)
lr
I

I'
I
I - Noto -
I Thir moa3uremont it always made without any
I
gnsket on air horn..
L-_

Fig,6-93
3. Adlust the clearance by bending at poirrt A
of the f loat as shown in the f igure.

L
F i9.,6-94
Adjust lowered positi$n of the float.
ffi l. Lift the float Fnd
between the n*$t,
check the clearance
valve plunger and float
*
lip with SST. 0
ssT [09240000201 t
Lowered position clearance:
0.9 - 1,6 mm (0.035 - 0.063 in. )

\r
{
'1.
t
Fig.6-95 r
r- 2, Adjust the
F

cleararfce by bending tab B of rhe

F
I

t
I
I
I
float as shown in lne f igu re. I
I
I
 'T
*
FUEL SYSTEM - Carbureror (Wirhout High Spoed Valvsl 6--36

!}
Body & Air Horn
Assemble tlre parts in the numerical orcfcr slror,vrr
in the figqre.
F ig. 6-96

1 rig. o,gz

c@b A.

t. Air Horn Fmt ldfa Crrn Connscting Link

2. Hose & Thermortatic Valve furnp Connccting Link
3^ Throt tle Poritioner Pump Arm Sct Scrcw
Brck Epring

6-97
Assernble the bsdy and alr horn with a new
gasket.

- Caution -
1. Takr sar! not to'demrgn thc ptf mp pfungnr
teatfier.
2, ArremHc thr rlr horn wfth the pump fot
poaitionod correctly.

t
I I
 t
'6- 36 FUE L SYSTEM - Carburotor (Without High Spesd Vclve)
ig, 6'98
t
F ADJUSTMENT
Use SST to make adjustments.
ssr toe2Ao-oool4l
t0s240-0m201

F ig. 6-99
Primary throttle valve opening
(l ) Fully open the primary throttle vatve.
l2l Check the primary tlrrottle valve oPen'
ing angle.
Opening angle: 90o

.il

,
o
? F
(31 Adjust bt bending the throt tle lever
stopper,
tf
*

.t

f
\ lr
l)
t\

,B
\ {
Fig.6.101 D
I
0 Fi
i,
l,

va f ve.
I

l'
(3) Check the throttle valve openinE
angf e;
Opening angle:
KP Serier {USA, CanEda} 75
KE, KP Serier (Others 4K) 80
KE, KP Series (Others 4K.Cl 90
KM Serier 90
 *
FUEL SYSTEI/I - Carbureror (Without High Speed Valve) 6 -37
t Fig.6'X02
(41 Adjust by .bendtng the throt tlc 1,.)\,8r,,
stopper.

o
F ig. S'103 I
tFr
,dt 3. Secondarftrf)i touch angfe
\ (l ) opdlr the prirnary throttle vrrve trnr il
valve tever A rour:rres rr, ;rs
ll]il::orrtc

tt

't
I
ir

r|
h

Fig.6'104 .l
I

* Ql At (tris time, check the prirrrary throt.

tle valve opening angf e.
Secondary touch angf e: S0o
I

(3) Adiust by bending A, as shorr,,n

:
I

*l
r

C
6- 38 F UE L SYSTEM * Carburetor (Without High:Speed Valve)

I
Fig. 6- 106
ick-up
A4
K
(l ) Open the primary throttle valve until
the k ick arm slightly opens the sec'
ondary throttle valve. '

F is. 6.107
r-*- l2l Check the clearance bel,ween the
ssr second ary throttle valve and body
with SST.
ssr [092400020]
Kick.up clsarance:
KP Seriel (USA, Canada) 2go
KE, KP Serier (bthers 4Kl 230
KE, KP Seriol (Others 4K'Cl 21"
KM Serieg (4K, 4K'C, sK'C) 230
KM Serier (5 K ) 2'lo
-\i I

F is 6'108
(3) Adiust by bending A, as shown. *
a

Fig.6-l0g Fi
idle
I

A5' i"i' Fully closeothe choke valve by turning

the choke $af t leverr fi
:

(2) Sct tlre ttrrpttle shaft lcvcr to tlrcr fasr

iclltl Cil rt. U
\_. tt v
t=

.l
I

I
I
t
,

rt

I
,.
l.
t FUEL SYSTEM - Carburotor {Without High,Spsod Vofvol 6139
,
t F ig'
''
af 'I
i (3) At this time, check the ptilt^tJ throt'
tle valve oPening angle with SST'
ssr [0924S000141 .
Fast idle angle: 24 - 26o

a
'l
o

0 ,!

c
(4) Adiust by turning the fast idte adiust-
ing screw.

t.

F
r.
1,1

)
II

6-1 12 :

6. Choke Opener or Choke Breaker (Australia

* 4 K-Cl
(l ) Fully close the choke valve
t

Fig, 6-113
(21 Apply vacuum to the diaPhragm.
(31 Check the choke valve opening angle
wittr SST.
ssr [09240-000141
Choko vrlvc oPoning angle:
Chokr OPenrr: 72"
Chokr Brukrr:
4K, 4K.C 43 - 44"
5K, sK'C 400.

t
{

{}
FUE L SYSTEM * Carburetor (Without High Speed Valvel

l-
Flg. 6- l l4
(4) Adiust by bending ihe connecting link
A, as shown,

..-
Fig. 6- l 15
7 . Accelerating pump
Adjust the pumpostroke by bending parr A,
as shown. e
Pump stroke: A
KP Series (ttSA, Canadal
$bO mm (0.1969 in.l
Others 2.75 - 3,25 mm
(0.1083 0,1280 in,l
-
- Noto -
After rdjurtment, b8 ruru to check thr linksge to
rs thst it operstil rmbothly.
,,n 6'll6
r- 6. fdle mixture aOjt$ring screw (Except USA)
I
{l } Tighten thfit idle mixture adjusrirrg *
screw to f uf v ctosed position anct then
unscrew it I as f ollows wi rh SST or I
screwdr iver.'
ssT [09243-000201
Approx, 3 turnr
i - Caution -
i
t
1 . Use cara not to tcrsw in: too tightly and
I damage thb rcrow tip.
I
I

i
i,- *
Irlle Nlr r,ture Adjusting SCrew 2, For USA rpecificationr, reter to the emission
control manuat, if necesrary,.
Fig. 6-1 17
r Install the ne\^/ lirrrik:r cap on tlre: irllc
QI
rrri:<ture aCljustirrr; screw

I
I

I
t
L_