Inspection and Adjustment

1.    Examine the carburetor body and fuel passages. If contaminated, wash the carburetor in a petroleum-based solvent. Do not use caustic carburetor cleaning solutions. Blow out all passages and jets with compressed air.

2.    Examine the condition of the floats. If the floats are damaged, they should be replaced.

3.    Inspect the float needle valve and seat for wear or contamination. Replace these components as a set.

4. Inspect the vacuum piston and rubber diaphragm. If the piston is scratched or the diaphragm is torn, the assembly must be replaced.

1. Vacuum piston               3. Set spring

2. Needle Jet

5. Inspect the starter plunger for damage, If damaged, replace.

E. Adjustment

Fuel level

NOTE:
Before checking the fuel level, note the following:

1.    Place the motorcycle on a level surface.

2.    Adjust the motorcycle position by placing a suitable stand or a garage jack under the engine so that the carburetor is positioned vertically.

1.    Connect the level gauge adapter (special tool) to the carburetor drain hole.

2.    Connect the level gauge (special tool) or a vinyl pipe of 6 mm (0.24 in) in inside dia. to the level gauge adapter.

3.    Set the gauge as shown and loosen the drain screw.

1. Level gauge adapter 2. Level gauge 3. Drain screw

4. Start the engine and stop it after a few minutes of running. This procedure is necessary to obtain the correct fuel level. Make sure the fuel petcock is "ON" or "RES" position.

5. Note the fuel level and bring the gauge to the other end of the carburetor line and repeat step 4 above. Note the fuel level again and compare it with the previous gauge reading. They should be equal. If not, place a suitable size of wooden piece or the life under the center stand and adjust.

6. Check the fuel level one by one. The level should be in the specified range.

Fuel level: 2 ± 1 mm (0.079 ± 0.039 in) below from the carburetor mixing chamber body edge.

7.    If the fuel level is incorrect, remove the carburetor assembly from the motorcycle and check the fuel valve(s) and float assembly(s) for damage.

8.    If no damage is found, correct the fuel level by slightly bending the float arm tang. Recheck the fuel level.

1. Float arm tang