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TVS – 811 Series Trap Valve Station Installation, Operation and Maintenance Instructions

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Filed Under (TVS) by admin on 29-04-2012

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In a piston valve, the control of stem and seat leakage is obtained by tightness of the valve sealing rings to the body and valve plug. The bonnet compresses the valve sealing rings against the body and the valve plug. Flexible disc springs automatically assure a tight seal by exerting pressure on the valve sealing rings, keeping them compressed. Opening and Closing the TVS Isolation Valves The isolation valve begins to stop flow when the valve plug enters the lower valve sealing ring. When the isolation valve is completely closed, the valve plug is in contact with the full height of the valve sealing rings, ensuring the best possible seal. In fact, there is no advantage to be gained in torqueing the valve closed. Armstrong recommends that after closing the isolation valves completely, the handwheel should be turned back one half turn. This makes it easy to re-open the valve by avoiding metal to metal seizure. Troubleshooting – Isolation Valves A piston valve will retain its leak tightness for several years without maintenance. In severe service, such as rapid heating and cooling, some field maintenance may be required. Depending on the problem, these simple steps may help: ! ! ! ! ! Isolation Valve leaks, when the valve is closed . First, Check to make sure the valve is actually closed . Check to see if bonnet is seated on the body, if not, tighten the bonnet nuts until the bonnet seats. This recompresses the valve sealing rings against the body and the valve plug. If valve continues to leak, replace the isolation valve assembly

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2008 KTM Model Engine Oil Recommendation Chart

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Filed Under (KTM) by admin on 24-11-2010

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2008 Model Type Recommended Engine Oil Type Quantity SPORTMINICYCLES AC 50 SX MINI Motorex ATF Super (Dexron II Gear Oil) 0.15-0.2 L SPORTMINICYCLES LC 50 SX JUNIOR Motorex ATF Super (Dexron II Gear Oil) 0.15-0.2 L 50 SX Motorex ATF Super (Dexron II Gear Oil) 0.15-0.2 L 65 SX Motorex Top Speed 4T 15W50 0.5L SX 2 STROKE 85 SX Motorex Top Speed 4T 15W50 0.5 L 105 SX Motorex Top Speed 4T 15W50 0.5 L 125 SX Motorex Top Speed 4T 15W50 0.7 L 144 SX Motorex Top Speed 4T 15W50 0.7 L 250 SX Motorex Top Speed 4T 15W50 0.7 L SX 4 STROKE 250 SX-F Motorex Power Synt 4T 10W50 1.1 L 450 SX-F Motorex Power Synt 4T 10W50 1.35 L 505 SX-F Motorex Power Synt 4T 10W50 1.35 L CROSS COUNTRY 2 STROKE 65 XC Motorex Top Speed 4T 15W50 0.5L 85 XC Motorex Top Speed 4T 15W50 0.5L 105 XC Motorex Top Speed 4T 15W50 0.5 L 200 XC Motorex Top Speed 4T 15W50 0.7 L
200 XC-W Motorex Top Speed 4T 15W50 0.7 L 250 XC Motorex Top Speed 4T 15W50 0.7 L 250 XC-W (e) Motorex Top Speed 4T 15W50 0.7 L 300 XC Motorex Top Speed 4T 15W50 0.7 L 300 XC-W (e) Motorex Top Speed 4T 15W50 0.7 L CROSS COUNTRY 4 STROKE 250 XC-F Motorex Power Synt 4T 10W50 1.1 L 250 XC-F-W Motorex Power Synt 4T 10W50 1.1 L 450 XC-F Motorex Power Synt 4T 10W50 1.35 L 450 XC-W (R) Engine – Motorex Power Synt 4T 10W50 Gearbox – Motorex 4T 10W50 0.7 L 0.9 L 505 XC-F Motorex Power Synt 4T 10W50 1.35 L 530 XC-W (R) Engine – Motorex Power Synt 4T 10W50 Gearbox – Motorex 4T 10W50 0.7 L 0.9 L ENDURO RACING 450 EXC (R) Engine – Motorex Power Synt 4T 10W50 Gearbox – Motorex 4T 10W50 0.7 L 0.9 L 530 EXC (R) Engine – Motorex Power Synt 4T 10W50 Gearbox – Motorex 4T 10W50 0.7 L 0.9 L SUPERMOTO LC4 690 Supermoto Motorex Power Synt 4T 10W60 Approx. 2.0 L SPORT ATV 450 XC Motorex Power Synt 4T 10W50 2.0 L 525 XC Motorex Power Synt 4T 10W50 2.0 L LC8 950 Super Enduro (R) Motorex Power Synt 4T SAE 10W50 (for temperatures over 32° F) and 5W40 (for temperatures under 32° F) Approx. 3.0 L 990 Adventure Orange Motorex Power Synt 4T SAE 10W50 (for temperatures over 32° F) and 5W40 (for temperatures under 32° F) Approx. 3.0 L 990 Adventure Black Motorex Power Synt 4T SAE 10W50 (for temperatures over 32° F) and 5W40 (for temperatures under 32° F) Approx. 3.0 L 990 Adventure S Motorex Power Synt 4T SAE 10W50 (for temperatures over 32° F) and 5W40 (for temperatures under 32° F) Approx. 3.0 L 990 Super Duke Motorex Power Synt 4T SAE 10W50 (for temperatures over 32° F) and 5W40 (for temperatures under 32° F) Approx. 3.0 L 990 Super Duke R Motorex Power Synt 4T SAE 10W50 (for temperatures over 32° F) and 5W40 (for temperatures under 32° F) Approx. 3.0 L

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CYLINDER HEAD REPAIR MANUAL

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Filed Under (Tips and Review) by admin on 28-10-2010

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ADJUSTABLE CYLINDER HEAD STAND Head can be rotated 360 degrees. Stays in any position using a simple locking mechanism. Use on twin or four cylinder heads. Shipping weight: 14 lbs. Adjustable length-10-1/2″ to 20-1/2″ long x 14″ width x 10-3/4″ high. 35-8602 Cylinder Head Stand VALVE GUIDE DRIVERS Use for removal and installation of valve guides into cylinder head. Available in the following sizes: 35-8418 4.5mm YM-4116 35-8416 6mm YM-4064-A 35-8417 5mm YM-4097 35-8414 7mm YM-1225-A 35-8408 5.5mm YM-1122 35-8413 8mm YM-1200 VALVE GUIDE DRIVER SET (REMOVE & REPLACE) Designed for speed and accuracy, this eleven piece set provides the right tool for the job. Driver set includes two valve guide drivers (5.5mm and 6.6mm), four valve guide installers, one cutter, three cutter pilots (5.5mm, 6.6mm, and 7.7mm) and one tap handle extension bar. 35-9445 Valve Guide Driver Set YAMAHA VALVE GUIDE INSTALLERS These installers are used for installation of Yamaha shoulder less valve guides to a specific depth into the cylinder head. To use, position onto the valve guide and drive into the cylinder head until installer makes contact with cylinder head surface. Note: Must use with Valve Guide Driver. Available in the following sizes: 35-8439 4.5mm YM-4117 35-8437 5.0mm YM-4098 35-8419 5.5mm YM-4015 35-8435 6mm YM-4065-A 35-8423 7mm YM-4017 VALVE GUIDE REAMERS Reaming valve guides after installation assures a proper valve stem to valve guide fit. Available in the following sizes: 35-3829 4.5mm YM-4118 35-3851 7mm YM-1227 35-3836 5.5mm YM-1196 35-3852 8mm YM-1211 35-3847 6mm YM-4066 CLOVER VALVE LAPPING COMPOUND KIT The world famous green can with the four leaf clover. For seating valves, mating gears, and sharpening. Sold as a kit with coarse 120 grit (roughing) and 280 fine grit (finishing). 35-0309 Clover Valve Lapping Compound VALVE LAPPING TOOL The ultimate vacuum stick for insuring perfect surfaces on valves and valve seats. Interchangeable cups make unit suitable for use with virtually any size valve. Set includes vacuum stick, 3/4″ and 1/4″ diameter rubber cups. 35-8998 Valve Lapping Too

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KTM OM-2 Split Body Floating Ball Valves Installation and Maintenance Instructions

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Filed Under (KTM) by admin on 26-01-2012

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Remove the valve from the shipping package (box or pallet) with care taken to avoid any damage to the valve and actuator (plus accessories where applicable). •Before installation, remove the seal discs from the flange. Clean the inside of the valve using an air line that includes an appropriate air-filter. Ensure that there are no solid objects such as pieces of wood, plastic or packing materials within the valve or on the valve seat. •Confirm that the materials of construction listed on the valve nameplates are appropriate for the service intended for and are as specified. When in doubt contact KTM, or your local Tyco facility. •Define the preferred mounting orientation with respect to the system pressure. The arrow on the body helps to identify the upstream side (high pressure) and downstream side (low pressure). •Ensure that all stud bolts and nuts of the body joint are firmly fastened. Caution •Verify that the direction of the flow in the line corresponds to the arrow indicated on the valve body. Valves without the arrow are bi-directional. •See the Actuator User Manual for the actuator preparation. 2.2. Installation Instructions •Ball valves are normally installed in horizontal pipes with the stem facing up. However, there are no limitations regarding the pipe or stem orientation. •Unless otherwise recommended by KTM, the valve should be installed with the ball in the open position, to ensure that the seat rings are not damaged during installation. •Particular care should be taken for valves equipped with “fail-close” actuators. •For operating temperatures above 200°C (392°F), thermal insulation of the valve body is recommended to protect the actuator/accessories from heat beyond the recommended temperature range. •Handling and lifting of the valves during installation MUST be performed following the same criteria and instructions described in points 1.2. and 1.3

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1998 YAMAHA YZF-R6 SERVICE MANUAL

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Filed Under (Yamaha) by admin on 25-11-2010

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Camshafts Drive system Camshaft cap inside diameter Camshaft journal diameter Camshaft-journal-to-camshaftcap clearance Intake camshaft lobe dimensions Measurement A Measurement B Measurement C Exhaust camshaft lobe dimensions Measurement A Measurement B Measurement C Max. camshaft runout Chain drive (right) 23.000 23.021 mm 22.967 22.980 mm 0.020 0.054 mm 33.05 33.15 mm 25.14 25.24 mm 7.81 8.01 mm 32.55 32.65 mm 25.07 25.17 mm 7.38 7.58 mm 0.08 mm 33.0 mm 25.09 mm 32.50 mm 25.02 mm 0.06 mm
2-5 ENGINE SPECIFICATIONS SPEC Head Diameter Face Width Seat Width Margin Thickness Item Standard Limit Timing chain Model/number of links Tensioning system RH2015/120 Automatic Valves, valve seats, valve guides Valve clearance (cold) Intake Exhaust Valve dimensions 0.11 0.20 mm 0.21 0.30 mm Valve head diameter A Intake Exhaust Valve face width B Intake Exhaust Valve seat width C Intake Exhaust Valve margin thickness D Intake Exhaust Valve stem diameter Intake Exhaust Valve guide inside diameter Intake Exhaust Valve-stem-to-valve-guide clearance Intake Exhaust Valve stem runout Valve seat width Intake Exhaust 24.9 25.1 mm 21.9 22.1 mm 1.14 1.98 mm 1.14 1.98 mm 0.9 1.1 mm 0.9 1.1 mm 0.6 0.8 mm 0.6 0.8 mm 3.975 3.990 mm 3.960 3.975 mm 4.000 4.012 mm 4.000 4.012 mm 0.010 0.037 mm 0.025 0.052 mm 0.9 1.1 mm 0.9 1.1 mm 1.6 mm 1.6 mm 0.5 mm 0.5 mm 3.950 mm 3.935 mm 4.042 mm 4.042 mm 0.08 mm 0.1 mm 0.04 mm 1.6 mm 1.6 mm
2-6 ENGINE SPECIFICATIONS SPEC Item Standard Limit Valve springs Free length Intake (inner) (outer) Exhaust Installed length (valve closed) Intake (inner) (outer) Exhaust Compressed spring force (installed) Intake (inner) (outer) Exhaust Spring tilt Intake (inner) (outer) Exhaust Winding direction (top view) Intake Exhaust 37.0 mm 38.4 mm 41.7 mm 30.0 mm 32.5 mm 36.1 mm 69 79 N (7.0 8.0 kgf) 114 132 N (11.6 13.4 kgf) 160 184 N (16.3 18.7 kgf) Clockwise Clockwise 35 mm 36.5 mm 39.5 mm 2.5/1.6 mm 2.5/1.7 mm 2.5/1.8 mm Cylinders Cylinder arrangement Bore stroke Compression ratio Bore Max. taper Max. out-of-round Forward-inclined, parallel 4-cylinder 65.5 45.5 mm 12.4 : 1 65.50 65.51 mm 0.05 mm 0.05 mm

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2006 Model Engine Oil Recommendation Chart

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Filed Under (KTM) by admin on 26-11-2010

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2006 Model Type Recommended Engine Oil Type Quantity SPORTMINICYCLES AC 50 MINI ADVENTURE Motorex ATF Super (Dexron II Gear Oil) 0.15-0.2 L 50 SENIOR ADVENTURE Motorex ATF Super (Dexron II Gear Oil) 0.15-0.2 L SPORTMINICYCLES LC 50 SX JUNIOR Motorex Top Speed 4T 15W50 0.15-0.2 L 50 SX Motorex Top Speed 4T 15W50 0.15-0.2 L 65 SX Motorex Top Speed 4T 15W50 0.3L SX 2 STROKE 85 SX Motorex Top Speed 4T 15W50 0.5 L 105 SX Motorex Top Speed 4T 15W50 0.5 L 125 SX Motorex Top Speed 4T 15W50 0.7 L 250 SX Motorex Top Speed 4T 15W50 0.7 L SX 4 STROKE 250 SX-F Motorex Power Synt 4T 10W50 1.1 L 450 SX Motorex Power Synt 4T 10W50 1.25 L 525 SX Motorex Power Synt 4T 10W50 1.25 L CROSS COUNTRY 2 STROKE 200 XC Motorex Top Speed 4T 15W50 0.7 L 200 XC-W Motorex Top Speed 4T 15W50 0.7 L 250 XC Motorex Top Speed 4T 15W50 0.7 L 250 XC-W Motorex Top Speed 4T 15W50 0.7 L 300 XC Motorex Top Speed 4T 15W50 0.7 L 300 XC-W Motorex Top Speed 4T 15W50 0.7 L CROSS COUNTRY 4 STROKE 450 XC Motorex Power Synt 4T 10W50 1.25 L 525 XC Motorex Power Synt 4T 10W50 1.25 L ENDURO RACING 400 EXC Motorex Power Synt 4T 10W50 1.25 L 450 EXC Motorex Power Synt 4T 10W50 1.25 L 525 EXC Motorex Power Synt 4T 10W50 1.25 L ADVENTURE LC8 950 Adventure orange Motorex Power Synt 4T SAE 10W50 (for temperatures over 32° F) and 5W40 (for temperatures under 32° F) Approx. 3.0 L 950 Adventure black Motorex Power Synt 4T SAE 10W50 (for temperatures over 32° F) and 5W40 (for temperatures under 32° F) Approx. 3.0 L 950 Adventure S Motorex Power Synt 4T SAE 10W50 (for temperatures over 32° F) and 5W40 (for temperatures under 32° F) Approx. 3.0 L SUPERMOTO RACING 450 SMR Motorex Power Synt 4T 10W50 1.25 L 560 SMR Motorex Power Synt 4T 10W50 1.25 L SUPERMOTO LC4 625 SMC Motorex Power Synt 4T 10W50 Approx. 2.1 SUPERMOTO LC8 950 Supermoto orange Motorex Power Synt 4T SAE 10W50 (for temperatures over 32° F) and 5W40 (for temperatures under 32° F) Approx. 3.0 L 950 Supermoto black Motorex Power Synt 4T SAE 10W50 (for temperatures over 32° F) and 5W40 (for temperatures under 32° F) Approx. 3.0 L

KTM 250/ 300/ 380 SX,MXC,EXC ENGINE REPAIR MANUAL

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Filed Under (KTM) by admin on 12-11-2010

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Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 2-2C main jet jet needle jet needle air control screw idle adjusting screw idle jet throttle valve Idling range A Operation with closed throttle valve. This range is influenced by the position of the air control screw 1 and the idle adjusting screw 2 . Only make adjustments when the engine is hot. To this end, slightly increase the idling speed of the engine by means of the idle adjusting screw. Turning it clockwise produces a higher idling speed and turning the screw counterclockwise produces a lower idling speed. Create a round and stable engine speed using the air control screw (basic position of the air control screw = open by 1.5 turns). Then adjust to the normal idling speed by means of the idle adjusting screw. Opening up B Engine behavior when the throttle opens. The idle jet and the shape of the throttle valve influences this range. If, despite good idling-speed and part-throttle setting, the engine sputters and smokes when the throttle is fully opened and develops its full power not smoothly but suddenly at high engine speeds, the mixture to the carburetor will be too rich, the fuel level too high or the float needle is leaking. Part-throttle range C Operation with partly open throttle valve. This range is only influenced by the jet needle (shape and position). The optimum part-throttle setting is controlled by the idling setting in the lower range and by the main jet in the upper range. If the engine runs on a four-stroke cycle or with reduced power when it is accelerated with the throttle partly open, the jet needle must be lowered by one notch. If then the engine pings, especially when accelerating under full power at maximum engine revs, the jet needle should be raised. If these faults should occur at the lower end of the part throttle range at a four-stroke running, make the idling range leaner; if the engine pings, adjust the idling range richer. Full throttle range D Operation with the throttle fully open (flat out). This range is influenced by the main jet and the jet needle. If the porcelain of the new spark plug is found to have a very bright or white coating or if the engine rings, after a short distance of riding flat out, a larger main jet is required. If the porcelain is dark brown or black with soot the main jet must be replaced by a smaller one. mixture too rich: too much fuel in proportion to air mixture too lean: not enough fuel in proportion to air 1 2 OPERATING RANGES OF THE CARBURETOR 2-3C Carburetor adjustment Basic information on the original carburetor setting The original carburetor setting was adapted for an altitude of approx. 500 meters (1600 ft.) above sea level, and the ambient temperature of approx. 20°C (68°F), mainly for off-road use and central European premium-grade fuel (ROZ 95 MOZ). Mixing ratio 2-stroke motor oil : super fuel 1:40 – 1:60. Basic information on a change of the carburetor setting Always start out from the original carburetor setting. Essential requirements are a clean air filter system, air-tight exhaust system and an intact carburetor. Experience has shown that adjusting the main jet, the idling jet and the jet needle is sufficient and that changes of other parts of the carburetor will not greatly affect engine performance. RULE OF THUMB:

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2003 SUZUKI SV 650 FUEL SYSTEM AND THROTTLE BODY SERVICE MANUAL

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Filed Under (Suzuki) by admin on 26-02-2011

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FUEL PUMP The electric fuel pump is mounted at the bottom of the fuel tank, which consists of the armature, magnet, impeller, brush, check valve and relief valve . The ECM controls its ON/OFF operation as controlled under the FUEL PUMP CONTROL SYSTEM . When electrical energy is supplied to the fuel pump, the motor in the pump runs and together with the impel- ler . This causes a pressure difference to occur on both sides of the impeller as there are many grooves around it . Then the fuel is drawn through the inlet port, and with its pressure increased, it is discharged through the outlet port . The fuel pump has a check valve to keep some pressure in the fuel feed hose even when the fuel pump is stopped . Also, the relief valve is equipped in the fuel pump, which releases pressurized fuel to the fuel tank when the outlet of the fuel pressure has increased up to 450 -600 kPa (4.5- 6.0 kgf/cm2,64- 85 psi) . Relief valve Brush , ∎ I,’ Check valve Magnet L Armature When the impeller is driven by the motor, pressure differential occurs between the front part and the rear part of the blade groove as viewed in angular direction due to fluid friction . This process continuously takes place causing fuel pressure to be built up . The pressurized fuel is then let out from the pump chamber and discharged through the motor section and the check valve . FUEL SYSTEM AND THROTTLE BODY 5- 3 Inlet port I I Impeller 5-4 FUEL SYSTEM AND THROTTLE BODY FUEL PRESSURE REGULATOR The fuel pressure regulator consists of the spring and valve . It keeps absolute fuel pressure of 300 kPa (3.0 kgf/cm2,43 psi) to be applied to the injector at all times . When the fuel pressure rises more than 300 kPa (3 .0 kgf/cm2, 43 psi), the fuel pushes the valve in the regulator open and excess fuel returns to the fuel tank . 90 Spring 02 Valve FUEL INJECTOR The fuel injector consists of the solenoid coil, plunger, needle valve and filter . It is an electromagnetic type injection nozzle which injects fuel in the throttle body according to the signal from the ECM. When the solenoid coil of the injector is energized by the ECM, it becomes an electromagnet and attracts the plunger. At the same time, the needle valve incorporated with the plunger opens and the injector which is under the fuel pressure injects fuel in conic dispersion . As the lift stroke of the needle valve of the injector is set constant, the volume of the fuel injected at one time is determined by the length of time during which the solenoid coil is energized (injection time)

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KTM ATV 525 XC specification

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Filed Under (KTM) by admin on 12-11-2010

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Engine ] Pure power for Enduro enthusiasts. The power of the 525 XC is the indisputable benchmark in the ATV Enduro sector. Its acceleration and top speed cast a shadow over all its predecessors. Variable ignition curves and perfect maintenance features like simple valve play adjustment and the removable clutch cover are even further highlights of the XC engine that make the KTM Enduro quads so superior. First Oil Filling for all KTM Engines. [ CarburEttor ] The Keihin carburettor, which has been proven multiple times in racing, with 39 mm and the Throttle Positioning System guarantees a uniform, forceful power delivery in all speed ranges. It ensures an unrivalled response behavior and perfect service-friendliness at all times. [ StartEr ] Packed in a space-saving manner into the free space behind the cylinder head, the small, light electric starter motor is ready for use. It brings every KTM ATV up to speed reliably and comfortably even when racing becomes hectic. [ rEar SuSPENSIoN ] Premium-quality ÖHLINS suspension components specially designed for tough Enduro use are provided as standard – both at the front and the rear. Easy to adjust, they guarantee optimal tuning for the most varied of terrains. Another highlight: the front and rear spring travel of 275 mm and 272 mm respectively is 100 % trend-setting for an Enduro ATV! [ alumINIum SubFramE ] The rear subframe is made of aluminium and is extremely light and easy to remove. [ FramE ] The lightweight, extremely durable frame sets the benchmark in the quad racing segment and is made of high-strength, powder-coated Chromoly steel. [ haNDlEbar ] An ultra-durable tapered aluminium Magura® handlebar comes standard that is four-position adjustable to suit your preferred ergonomics. Further highlights are the functional and individually adjustable operating levers for brake and hydraulic clutch. In addition, the chassis has an integrated mount for a steering damper – available as a PowerPart accessory. [ CurvED raDIator ] Best cooling by means of its curved shape and the resulting maximized surface area. [ rImS / tIrES ] MAXXIS Razr tyres on light, stable DWT aluminium rims. [ ExhauSt ] The powerful XC silencer is made of light-weight aluminium.

KTM 60 SX / 65 SX REPAIR MANUAL ENGINE

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Filed Under (KTM) by admin on 12-11-2010

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Carburetor adjustment Basic information about the original carburetor setting The original carburetor setting was adapted for an altitude of approx. 500 meters (1600 ft.) above sea level, and the ambient temperature of approx. 20°C (68°F), mainly for off-road use and central European premium-grade fuel (ROZ 95). Mixing ratio 2-stroke motor oil : super fuel 1:40 . Basic information of changing the carburetor setting Always start out from the original carburetor setting. Essential requirements are a clean air filter system, air-tight exhaust system and an intact carburetor. Experience has shown that adjusting the main jet, the idling jet and the jet needle is sufficient and that changes of other parts of the carburetor will not greatly affect engine performance. RULE OF THUMB: high altitude or high temperatures  choose leaner carburetor adjustment low altitude or low temperatures  choose richer carburetor adjustment * WARNING * -ONLYUSE PREMIUM – GRADE GASOLINE ROZ 95 MIXED WITH HIGH – GRADE TWO – STROKE ENGINE OIL . OTHER TYPES OF GASOLINE CAN CAUSE ENGINE FAILURE , AND USE OF SAME WILL VOID YOUR WARRANTY . -ONLYUSE HIGH – GRADE 2- STROKE ENGINE OIL OF KNOWN BRANDS ( I . E .SHELL ADVANCE RACING X). -NOTENOUGH OIL OR LOW – GRADE OILCAN CAUSE EROSION OF THE PISTON . USING TOO MUCH OIL , THE ENGINE CAN START SMOKING AND FOUL THE SPARKPLUG . -INTHE CASE OFA LEANER ADJUSTMENT OF THE CARBURETOR PROCEED CAUTIOUSLY . ALWAYSREDUCETHEJETSIZEINSTEPSOFONENUMBERTOAVOID OVERHEATING AND PISTON SEIZURE . NOTE: If despite a changed adjustment the engine does not run properly, look for mechanical faults and check the ignition system. Basic information on carburetor wear As a result of engine vibrations, throttle valve, jet needle, and needle jet are subjected to increased wear. This wear may cause carburetor malfunction (e.g., overly rich mixture). Therefore, these parts should be replaced after 1000 hours of using. Idling range – A Operation with closed throttle valve. This range is influenced by the idle adjusting screw 1 . Only make adjustments when the engine is hot. The idling speed can be changed by turning the idle adjusting screw. Turning it clockwise produces a higher idling speed and turning the screw counterclockwise produces a lower idling speed. Opening up – B Engine behavior when the throttle opens. The idle jet and the shape of the throttle valve influences this range. If, despite good idling-speed and part-throttle setting, the engine sputters and smokes when the throttle is fully opened and develops its full power not smoothly but suddenly at high engine speeds, the mixture to the carburetor will be too rich, the fuel level too high or the float needle is leaking. Part-throttle range – C Operation with partly open throttle valve. This range is only influenced by the jet needle (shape and position). The optimum part-throttle setting is controlled by the idling setting in the lower range and by the main jet in the upper range. If the engine runs on a four-stroke cycle or with reduced power when it is accelerated with the throttle partly open, the jet needle must be lowered by one notch. If then the engine pings, especially when accelerating under full power at maximum engine revs, the jet needle should be raised. If these faults should occur at the lower end of the part throttle range at a four-stroke running, make the idling range leaner; if the engine pings, adjust the idling range richer

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