Carburetor Repair Manual

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Carburetors Contents 1. Safety Precautions 2 7. 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11 7.12 7.13 7.14 7.15 7.15.1 7.16 14 7.16.1 7.16.2 7.17 7.18 7.18.1 Servicing 25 7.19 7.19.1 Standard Setting on Zama Carburetors 54 C1Q-S30C, C1Q-S37A, C1Q-S41, C1Q-S42, C1Q-S34B, C1Q-S36B Fixed Jet Carburetors 54 C1Q-SK7, C3A-S39A Carburetors with Limiter Caps 55 Standard Setting on Tillotson Carburetors 59 Fixed Jet Carburetors: HS-275A, HS-279B 59 HL-366A, HS-280A, HS-281A, HT-12A Carburetors with Limiter Caps 60 Flow Chart 64 Special Servicing Tools and Aids
2.
Introduction
3. 3.1
Assignment Designation
3 8
4.
Purpose of Carburetor
5. 5.1 5.2 5.2.1 5.2.2 5.2.3
Construction/Function 9 Fuel Pump Operating Conditions Full Load Idle Carburetor with Fixed Idle Jet and Primary Mixture Control Carburetor with Balanced Idle System (Fixed Idle Jet and Air Bypass System) Part Load Problematic Operating Conditions Starting Temperatures/ Humidity Acceleration Dirty Air Filter/ Compensator Special Features 9 11 11 12
5.2.4
5.2.5 5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.4
15 16 17 17 19 19 20 21
7.18.2
6.
Troubleshooting Chart
23
Leakage Test 25 Cleaning 25 Pump Diaphragm 26 Metering Diaphragm 26 Inlet Needle 27 Main Jet 28 Full-Load Fixed Jet/ Part-Load Fixed Jet 29 Control Valve 29 Manual Fuel Pump 30 Check Valve 30 Carburetor Body 31 Throttle Shaft 32 Choke Shaft 34 Accelerator Pump 35 Lever Mechanism on Carburetors with Automatic Choke 36 Throttle Shaft/ Choke Shaft 38 HL-324A / HL-327D / LA-S8A Carburetors 38 Throttle Shaft 43 Choke Shaft 44 WYL-63 / WYL-73 Rotary Valve Carburetors 45 Standard Setting on Walbro Carburetors 50 WT-283B, WT-323, WT-325A, WT-326C, WT-360, WT-396, WT-403A, WT-493, WT-498A, WT-503 Fixed Jet Carburetors 50 HD-13A, HD-16, HD-17, HD-18A, HD-21A, HD-22, WY-69, WT-329, WT-330, WT-367, WT-393, WT-489, WT-492, WJ-69 Carburetors with Limiter Caps 51
7.19.2 7.20 7.20.1 7.20.2
7.21 8. 8.1 8.2
65
Special Servicing Tools 65 Servicing Aids 65
1999 Andreas Stihl AG & Co., Waiblingen
Carburetors
www.mymowerparts.com
Stihl
1.
Safety Precautions
2.
Introduction Symbols are used in the text and illustrations for greater clarity. The meanings are as follows: In the descriptions:
If the chainsaw or power tool is started up in the course of repairs or maintenance work, observe all local and countryspecific safety regulations as well as the safety precautions and warnings in the owners manual. Gasoline is an extremely flammable fuel and can be explosive in certain conditions. Improper handling may result in burns or other serious injuries. Warning! Do not smoke or bring any fire or flame near the fuel. All work with fuel must be performed outdoors only. Spilled fuel must be wiped away immediately. Warning! To avoid the risk of accidents and personl injury, take extreme care when performing adjustments without the cutting tool guard or deflector.
This service manual contains descriptions of repair and servicing procedures as well as functional diagrams of most carburetors used in STIHL gasoline power tools. While carrying out repair work you should make use of the latest illustrated parts list of the power tool concerned. It shows the installed positions and the assembly sequence of individual components and assemblies. Parts lists on microfilm and CD-ROM are always more up to date than printed lists. A fault on the carburetor may have several causes. Consult the troubleshooting chart - see 6. Refer to the "Technical Information" bulletins for engineering changes which have been introduced since publication of this service manual. Technical information bulletins also supplement the parts list until an update is issued. Service manuals and all technical information bulletins describing engineering changes are intended exclusively for the use of STIHL servicing dealers. They must not be passed to third parties.
= Action to be taken as
shown in the illustration (above the text) - = Action to be taken that is not shown in the illustration (above the text) In the illustrations: = Pointer = Direction of movement Always use original STIHL replacement parts. They can be identified by the STIHL part number, the lgo and the STIHL parts symbol The symbol may appear alone on small parts.
Carburetors
3.
Assignment
Model
Carburetor
Idle system with bypass air screw (LD) preliminary mixture control
Part load
Full load
Setting
Equipment
H unlimited adjustment
L unlimited adjustment
full-load semi-fixed jet
choke shutter in carb
H, L with limiter caps
manual fuel pump x x x x x x x
full-load fixed jet
009 ... 012 009, 010, 011 009, 011 009, 011 1) 017 017 019T 020 020 020T 020T 1) 020T 021 1) 021 021, 023 1) 021, 023, 025 023 023 023 023C 023C 023CZ 1) 023L 023L 1) 024 024 024, 026 025 025 025 025 025 025 026 026 1) 026 1) 026W/Pro 028
C1S-S1 WT-29A C1S-S1C 2) WT-323 WT-325A WT-325 C1Q-S37A WT-15A C1Q-S32 C1Q-S16A WT-326C WT-326 WT-503 WT-286A WT-283A C1Q-S11 WT-215 WT-283B WT-286A WT-286A WT-498 WT-498A WT-360 WT-396 WT-194 WT-110 WT-194 WT-215 WT-286A WT-396A WT-498A WT-283B WT-313 WT-426 WT-493 WT-403A WT-427 WT-16
x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x
x x x
x x x x x x x x x x x x x x x x x x x x x x x
x x x
x x x x x
x x x x x
x x
x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x
x x x x x x
Carburetors
Compensator x x x 3
independent
part-load jet
fixed idle jet
dependent
balanced
Model
Carburetor
Part load
Full load
Setting
Equipment
manual fuel pump
full-load fixed jet
029 029 1) 029, 039 034 034 034, 036 036 036 036 1) 036W 038 038 039 039 1) 044 044 044 044 044 044 1) 044 (SA) 046 046 1) 046 BR 051, 050, 076 056 056 064 064 064 064 064, 066 066 066 066 1) 066 BR 066 MW 070
HD-19B HD-18A HD-5 C3A-S38A C3A-S38 C3A-S19 C3A-S4C C3A-S31D C3A-S39A C3A-S27C HK-42 Bing 48 HD-19B HD-21A HD-10 HD-11 HD-15 C3M-S20 C3M-S5G HD-17 C3M-S21/S12 HD-14 HD-16 HD-24 HS-60D HS-118B WJ-4B WJ-48 WJ-51 WJ-52 WJ-65 WJ-35/41 WJ-66 WJ-67 WJ-69 WJ-76 WJ-66 LB-S9
x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x
x x x x x
x x x x x x x x x
x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x
x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x
x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x
x x x
x x x x x
x x x x x x x x x x x
x x x x
x x x x x x x x x x
x x x x x x x x x x
Carburetors
Compensator x x x x x x x x x x x x x x x x x x x x x x x x x x x
independent
part-load jet
fixed idle jet
dependent
balanced
Model
Carburetor
Part load
Full load
Setting
Equipment
manual fuel pump x x x x x x x x x x
full-load fixed jet
070 070, 090 08 084 088 1) 08S 08S 090 BG 72 BG 72 1) BG 75 BR 106 BR 320 1) BR 320 BR 320 L BR 320 L BR 320 L 1) BR 320 L BR 320, 400 1) BR 400 1) BR 400 BR/SR 320, 400 BT 106, 108 BT 360 FC 44 1) FC 72 FC 72 1) FR 106, 108 FR 108 FR 108 1) FS 106, 108 FS 120, 300 FS 120, 300 FS 160 FS 160, 180, 220 FS 200, 350 FS 220 FS 25-4
HL-324A HL-324A HL-166C HT-7A HT-12A LA-S8A IVH8 LB-S9 WT-253 WT-330 C1Q-S30C C1Q-SK6 HD-13A HD-4B WT-230 WT-230B WT-489 WT-331 HD-7 HD-13A HD-4B HD-4 C1Q-SK5 HL-327E WT-327 WT-227F WT-329 C1Q-SK5 C1Q-SK5 C1Q-SK7 C1Q-SK5 C1Q-S35B C1Q-S36D C1S-S3D C1S-S3C C1Q-S36D C1S-S3D WYL-63/-73
x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x
x x x x x x x x
x x x x x x x x x x
x x x x x x x x
x x x
x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x
x x
x x
x x x
Carburetors
Compensator x x x x x 5
independent
part-load jet
fixed idle jet
dependent
balanced
Model
Carburetor
Part load
Full load
Setting
Equipment
manual fuel pump x x x x x x x x x x x x x x x x x
full-load fixed jet
FS 280 FS 280 FS 36, 40, 44 FS 36, 40, 44 1) FS 36, 40, 44 FS 360, 420 FS 400 FS 450 FS 500 FS 500 FS 550 1) FS 550 FS 65-4 FS 72, 74, 76 FS 72, 74, 76 1) FS 75, 80, 85 FS 75, 80, 85 FS 81, 86 2) FS 86 2) FS 88, FR 88 1) FS 88, FR 88 2) FS/FR 108 1) HS 72, 74, 76 HS 72, 74, 76 1) HS 75, 80, 85 TS 350 TS 350 TS 350 1) TS 350 TS 360 TS 360 TS 360 TS 400 TS 400 TS 400 1) TS 460 TS 460 1) TS 460
C1S-S3D WT-223 WT-160B WT-492A WT-327 HD-3 C1Q-S34C C1Q-S34C HD-22 HD-23 HD-22 HD-23 WYL-63 WT-227F WT-393 C1Q-S41A WT-447 WT-112 WT-45A WT-367 WT-45A C1Q-SK7 WT-264 WT-329 C1Q-S42A HL-292 HL-292G HL-366A LAS6 HL-327D HL-327E LAS7 HS-274A HS-274D HS-279B HS-262B HS-275A HS-276D
x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x
x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x
x x x x x x
x x x x x x x x x x x x x x x x x x x x x x x x x x x
x x x x x x x x x x x x
x x x x x x
x x x x x x
x x x x x x
x x x x x x x x x x x x x
Carburetors
Compensator x x x x x x x x
independent
part-load jet
fixed idle jet
dependent
balanced
Model
Carburetors TS 510 TS 510 1) TS 510, 760 TS 760 TS 760 1)

1) 2)
HS-277A HS-280A HS-212B HS-277A HS-281A x x x x x x x x x x x x x x x x x x x x x x x x x x dependent independent fixed idle jet preliminary mixture control balanced with bypass air screw (LD) part-load jet full-load fixed jet full-load semi-fixed jet H unlimited adjustment L unlimited adjustment H, L with limiter caps choke shutter in carb manual fuel pump Compensator
Carburetor
CARB, EPA Accelerator pump
Idle system Part load Full load Setting Equipment
3.1
Designation
4.
Purpose of Carburetor As there is a lack of fuel, the engine does not produce its full power. Furthermore, the engine overheats because insufficient heat is dissipated to vaporize the fuel. The lack of fresh gas containing oil results in inadequate lubrication and a risk of seizure. A rich mixture contains less air. Combustion is incomplete. Apart from other effects, unburned fuel is seen as smoke at the exhaust. A certain amount of oil is added to the fuel for lubrication of the bearings and piston.
HT 7A WT 223
The carburetor has to mix fuel and air in an optimum ratio for each phase of engine operation. It prepares the mixture for vaporization by breaking it down into fine droplets. In the carburetor, fuel is atomized but not completely vaporized. The heat necessary to vaporize the fuel is taken from the components the fuel flows through, i.e. primarily the engine. Therefore, complete vaporization does not take place until the mixture reaches the combustion chamber. The absorption of vaporization heat by the fuel represents a form of cooling for the components that give off the heat. One talks about internal cooling. The ideal fuel-air ratio (Lambda () = 1) is reached when the composition of the mixture is 14.8 kg air to 1 kg fuel. Fuel burns cleanly at this mixture ratio. The mixture is combustible between Lambda 0.7 and 1.25. The mixture ratio deviates from the ideal value depending on the prevailing operating conditions (temperature, humidity, air pressure) and the operating phase (starting, idle, part load, full load). When the actual mixture ratio deviates from the ideal value, the mixture is said to be either rich or lean. A lean mixture contains more air.
915RA001 VA
The carburetor designation is stamped or printed on the body of some models (e.g. HT-7A or WT-223).
C3M
HD
L H H
On some models the family designation (e.g. C3M or HD) is integrally cast on the body.
S20
915RA003 VA
Other identification numbers are stamped on the body of such models (e.g. S 20) or printed (e.g. S36C).
915RA002 VA
Carburetors
5.
Construction/ Function
5.1
Fuel Pump Low pressure is created in the crankcase by the upward stroke of the piston. This causes the pump diaphragm (3) to flex. A vacuum is also created in the pumps fuel chamber (4). Atmospheric pressure in the tank now pushes fuel via the intake fitting (5) and inlet valve (6) into the fuel chamber (4). The outlet valve (7) is pressed against its seat and closes the passage to the fuel port (8). Note: The pump inlet and outlet valves are flaps stamped out of the pump diaphragm but still attached to it at one side.
In view of the machine applications, the carburetor must operate trouble-free in all positions. For this reason only all-position diaphragm carburetors with an integral fuel pump are used in STIHL outdoor power tools. Such carburetors have no float. The fuel pump operates as a completely separate unit even though it is integrated in the carburetor housing. The fuel pump is controlled by the changes of pressure in the cylinder and crankcase.
A carburetor consists of a hollow housing which has a special internal contour, i.e. the choke tube (venturi) (1). Engine intake air flows through this venturi. The smaller the cross section of the venturi, the greater the air flow speed and the vacuum created. Fuel jets open into the venturi at various points from which the airstream draws fuel. The fuel pump, nozzle or jet systems and metering devices for optimum preparation of the fuel-air mixture are integrated in or mounted on the carburetor. The flow of air, and thus engine power, is regulated by the throttle shutter (2).
6 5 8
915RA004 VA
6 5 8
915RA005 VA
Intake process The impulse chamber (1) is connected to the crankcase via the impulse port (2).
Delivery process The downward stroke of the piston creates an overpressure which presses the pump diaphragm (3) towards the fuel chamber. 9
Carburetors
The pump diaphragm therefore reduces the volume of the fuel chamber (4). Inlet valve (6) is now pressed against its seat and closes the passage to the intake fitting (5). The outlet valve (7) is lifted off its seat and allows a certain amount of fuel to flow into the fuel port (8) which leads to the carburetor inlet valve. Note: During each complete pump stroke an amount of fuel is delivered which is equivalent to the difference in volume between the two end positions of the pump diaphragm in the fuel chamber. On machines with a fuel tank mounted lower than the carburetor it is necessary to prime the carburetor with fuel after a prolonged out-of-service period by pulling the starter rope a few times. This problem can be overcome with a manual fuel pump (see below).
Atmospheric pressure is applied to the metering diaphragm through bore (4). If the machine is equipped with a compensator, the pressure prevailing at the clean side of the air filter acts on the metering diaphragm (see chapter 4.3.4). When air flows through the venturi, fuel is drawn out of the metering diaphragm chamber, i.e. the volume of fuel is reduced. The metering diaphragm is pushed upwards by atmospheric pressure. The metering diaphragm (2) applies pressure to the inlet lever (5) and thus lifts the inlet needle (6) off its seat. Fuel now flows from the pumps fuel chamber to the metering diaphragm chamber until the pressure in the metering diaphragm chamber is approximately equal to the pressure applied to the outside of the metering diaphragm. The metering diaphragm always allows a quantity of fuel to flow which is equal to that which is drawn out of the jets. Manual fuel pump Some carburetors (on power tools) are equipped with an additional manual fuel pump for priming the fuel system prior to starting. Note: On chainsaws the manual fuel pump is a separate component, i.e. it is not integrated in the carburetor. A vacuum is created in the metering diaphragm chamber when the pump bulb is released. This causes the metering diaphragm (1) to be pulled against the inlet control lever (2). The inlet needle (3) opens and fuel then flows from the pump chamber into the metering diaphragm chamber. Excess fuel pumped into the metering diaphragm chamber passes through the bore (4) to the valve. The valve tabs open and fuel flows into the pump bulb. When the pump bulb is pressed, fuel is pumped back into the tank via valve (2).
When the pump bulb (1) is depressed, the valve (2) opens and allows air or any fuel in the bulb to flow back to the tank via the fitting (3).
Inlet needle valve The chamber (1) above the metering diaphragm (2) is filled with fuel through port (3).
10
Carburetors
5.2 5.2.1
Operating Conditions Full Load
915RA009 VA
Check valve A check valve is installed in the metering diaphragm chamber of all carburetors equipped with an additional manual fuel pump.
Full load is the operating condition with the throttle shutter wide open. Fuel is drawn from the main jet (1) and the idle jets (2 and 3).
Full-load semi-fixed jet At full load, a defined quantity of fuel (approx. 80% at H = 1) is always pumped from the metering diaphragm chamber (3) via the fullload semi-fixed jet (1) and through the main jet (4) to the venturi, irrespective of the setting of the high speed screw (2). This means that the change in the composition of the mixture for a given adjustment of the high speed screw is far less than on a carburetor that has no full-load semi-fixed jet. The semi-fixed jet may be installed as a separate component or be integrated as a nozzle bore in the main jet. There is no direct connection between the separate semifixed jet and the venturi. It is connected to the main jet via a passage (5).
When the manual fuel pump is operated, the check valve (1) closes to prevent air being sucked into the metering diaphragm chamber from the venturi and the idle jet bores. During operation the check valve opens and allows fuel to flow to the main jet and the idle jet bores.
Main jet (valve jet) The main jet (1) is situated at the narrowest point of the venturi. It is at this point that air flow speed is highest and pressure is lowest. The main jet is equipped with a check valve (2) to prevent air being sucked into the metering diaphragm chamber at idle speed. The amount of fuel drawn in by the main jet can be adjusted with the high speed screw (3).
Full-load fixed jet On carburetors with a full-load fixed jet (1) all the fuel required for full-load operation flows via this jet. Carburetors 11
5.2.2 There is no high speed screw. The full-load setting cannot be altered. Like the semi-fixed jet, the full-load fixed jet may be installed as a separate component or be integrated as a nozzle bore (2) in the main jet. There is no direct connection between the separate fixed jet and the venturi. It is connected to the main jet via a passage (3).
Idle When the throttle shutter is closed there are two bores (secondary idle or bypass) (1 and 2) in front of it and one (primary idle) (3) behind it (viewed in the flow direction). In this position the air flow in the venturi is very slow and the vacuum is slight. Fuel is drawn only from the primary idle jet at the air gap between the throttle shutter and carburetor body.
The throttle shutter (1) alters the cross section of the venturi and thus regulates the flow of intake air. It is operated by the user via the throttle rod. The idle position of the throttle shutter is adjusted by means of the idle speed screw. The throttle shutter is almost closed. Air flows through a narrow gap between the throttle shutter and venturi. Fuel is drawn from the primary idle jet (2). There is only a slight vacuum in the area of the main jet (3) so no fuel flows at this stage.
As a result of the difference in pressures (pressure in front of throttle shutter is close to atmospheric pressure), air from the venturi passes through the secondary idle jets (bypass bores) (1 and 2) into the idle chamber (4). This air mixes with the fuel and is drawn out of the primary idle jet (3) as a fuel-air mixture at the low pressure side. In this process more air is added to the relatively small amount of air which flows through the small notch or hole in the throttle shutter and only the quantity of fuel required for idling is drawn off.
Idle jets - bypass bores

1 2 3 12 3 5
915RA184 BL
There are two or three idle bores in the area of the throttle shutter.
When the throttle shutter is opened the vacuum acts on the area of the secondary idle jets (1 and 2). Fuel is then drawn from these bores as well.
12
Carburetors
915RA185 BL
12
As the quantity of air that flows through the venturi is now greater, this fuel is necessary to enrich the mixture during acceleration. The amount of fuel drawn from idle jets (1, 2 and 3) can be increased or decreased by means of the low speed screw (5) whose pointed tip varies the size of the passage to the idle chamber (4).
915RA185 BL
Idle system independent of main jet system In these carburetors the main jet and idle systems are arranged in parallel. Changes in the idle fuel volume mean a change in the full-load fuel volume. If the idle fuel volume is altered with the low speed screw (2), it is necessary to readjust the high speed screw (1). When the idle setting is made leaner, the overall fuel-air mixture becomes leaner too. This increases engine speed as well as the risk of engine damage as a result of overheating.
Idle system dependent on main jet system In these carburetors the idle system branches off the full-load system after the high speed screw (1). It is not directly connected to the metering diaphragm chamber. Full-load fuel flow is determined by the high speed screw. Adjusting the low speed screw (2) to change the idle fuel volume does not result in a change to the overall fuel volume.
Carburetors
13
5.2.3
Carburetor with Fixed Idle Jet and Primary Mixture Control The proportion of primary mixture in the idle mixture can be adjusted with the idle screw (7) (primary mixture control). The machine will run with the basic setting (approx. 1 turn open). The idle mixture is made richer by opening the idle screw (7) or leaner by closing the screw. If necessary, the idle speed can be adjusted with the idle speed screw (LA). Reduced sensitivity to temperature Carburetors with fixed idle jets ensure a much steadier idling behavior at low temperatures: Fuel becomes viscous at lower temperatures.
Idle In the idle positon, the throttle shutter is situated between the 2nd secondary idle jet (5) and the primary idle jet (6). The pressure in front of the throttle shutter is close to atmospheric pressure, while the vacuum created by the engine prevails behind the throttle shutter. Vacuum acts on the idle chamber (3) via the primary idle jet (6). As a result of the pressure differential, air flows from the venturi through the secondary idle jets (4 and 5) into the idle chamber (3). At the same time, fuel is drawn out of the metering diaphragm chamber (1) and into the idle chamber (3) via the fixed idle jet (2). A primary mixture is created in the idle chamber (3) which is sucked through the primary idle bore (6) into the area at the engine side of the throttle shutter. The idle air is drawn through a notch or a hole in the throttle shutter and mixes with the primary mixture to form the idle mixture. Transition from idle to part load When the throttle shutter is opened, vacuum acts on the secondary idle jets (4 and 5). Fuel is then drawn from all three idle jets (4, 5 and 6). Transition from part load to full load The main jet begins to deliver fuel when the throttle shutter has opened about 20 degrees. The idle and full-load system deliver the optimum amount of fuel to suit given opening conditions when the throttle shutter is opened fully. Advantages over conventional carburetors The fixed idle jet (2) limits enrichment for acceleration and the amount of fuel that flows via the idle system during full-load operation. As a result, the setting of the idle screw (7) has no effect at all on the volume of fuel at full load.
1
2
915RA292 VA
The more viscous the fuel is, the greater the influence the shape of the throttle orifice has on the flow rate. Conventional adjusting screws create an annular gap (1) at the throttle orifice which can become blocked within a relatively short time. Fixed jets have a round cross section (2) at the throttle orifice which allows a constant flow of fuel even at low temperatures. A constant fuel flow rate is the precondition for a steady idling behavior.
14
Carburetors
5.2.4
Carburetor with Balanced Idle System (Fixed Idle Jet and Air Bypass System) Most of the air required to form the idle mixture flows through the hole in the throttle shutter. The air required to adjust the idle speed is sucked in via the idle chamber - or air bypass port. The amount of bypass air can be adjusted with the idle speed screw (LD screw). If pressure P11 in air bypass chamber (11) is - lower than the atmospheric pressure in front of throttle shutter (7), air flows through bypass port (9) into the air bypass chamber (11) - greater that pressure P3 in idle chamber (3), air flows from bypass chamber (11) through the connecting passage (4) to the idle chamber (3). The idle chamber (3) receives air via the secondary idle bore (5) as well as the connecting passage (4). At the same time, fuel is drawn out of the metering diaphragm chamber (1) via the fixed idle jet (2). A primary mixture is formed in the idle chamber (3) which is sucked through the primary idle bore (6) into the engine side of the throttle shutter. Primary mixture, air from the bypass port (10) and the air which flows through the hole (8) in the throttle shutter mix together to form the idle mixture. Low engine idle speed, the LD screw restricts the air bypass port: The vacuum Pu behind the completely closed throttle shutter (7) causes - air to flow through the hole (8) in the throttle shutter - vacuum P3 in idle chamber (3) via the primary idle bore (6) - vacuum P11 in air bypass chamber (11) via the bypass port (10). Higher engine idle speed The LD screw is turned clockwise to increase idle speed. Note: The LD screw has a lefthand thread in order to retain the familiar directions of rotation for adjustments: - Rotating the screw clockwise increases engine speed. - Rotating the screw counterclockwise reduces engine speed. Turning the LD screw clockwise reduces the pressure P11 in the air bypass chamber (11). This increases the air throughput in bypass port (10). The difference between P3 and P11 becomes smaller so that less air flows through the connecting passage (4) to the idle chamber.
The graph shows the air-fuel ratio (Lambda ) or the carbon monoxide content (CO) in the exhaust gas plotted against the idle RPM: Carburetors with a balanced idle system (BIS) guarantee an ideal idle mixture at all idle speeds. Benefits These carburetors are characterized by: - Smooth, uniform idle speed - Good response and acceleration - Lower emissions under all operating conditions - Stable adjustment over a wide ambient air temperature range - Only one adjusting screw makes adjustment simpler. Special features A fixed idle jet and an air bypass system with calibrated bores are typical features of carburetors with a balanced idle system. The throttle shutter is completely closed in the idle position.
Carburetors
15
5.2.5
Part Load The low pressure causes additional fuel to be drawn off and enrich the fuel-air mixture in response to the throttle shutter position.
The flow of air in connecting passage (4) stops when P3 and P11 are equal.
Part load means all stages of engine operation with a partly opened throttle shutter. Fuel is drawn from the primary idle jet (1) and the secondary idle jet (2). Part-load fixed jet When working in the part-load range (e.g. limbing) the throttle shutter is often in a position between idle and full throttle. In this situation the fuel-air mixture may become over-lean ("part-load flat spot") and there is then a danger of seizure.
Turning the LD screw further clockwise reverses the pressure gradient. P11 is then lower than P3 so that primary mixture from the idle chamber (3) is added to the bypass air flowing through bypass ports (9 and 10) via the connecting passage (4).
The part-load fixed jet (1), which opens into the venturi between the idle jets and the main jet, prevents the mixture becoming over-lean.
16
Carburetors
5.3 5.3.1
Problematic Operating Conditions Starting The full vacuum acts on the idle jets (3 and 4) and main jet system (2) in the metering diaphragm chamber. Fuel is drawn in and mixed only with the air that flows through the notch or hole in the choke shutter. As soon as the engine has fired it is necessary to make the mixture leaner, i.e. open the choke shutter. The heat generated by initial combustion evaporates part of the fuel that had previously settled on the component walls. This has an enriching effect while the engine is warming up. Note: Once the engine is running, open the choke shutter immediately to avoid an over-rich fuel-air mixture (the engine would otherwise stall again).
915RA026 VA
Hot start Compared to engine idle RPM, the speed achieved by cranking the engine on the starter is very low. The gas flow speed and the vacuum in the venturi are therefore limited. Fuel and air mix poorly in this situation. Moreover, fuel is more sluggish than air. This means than considerably more air than fuel is sucked in, the mixture becomes too lean and does not burn well. Cold start During a cold start the problems described for a hot start are further amplified. Cold components cannot transfer heat to the mixture. As a result, the mixture gasifies poorly and a large proportion of the fuel condenses on the walls of the components it flows through.
Automatic choke Some machine versions are equipped with an automatic choke. It sets the throttle and choke shutters to the correct positions for an optimum mixture. Choke shutter and throttle shutter with bellows and control valve are connected via a lever mechanism on the carburetor.
The mixture in the carburetor has to be highly enriched for the cold start: the choke shutter (1) is closed.
Carburetors
17
1
37
The throttle shutter (1) is at an angle of 37 degrees to the carburetor mounting flange just before the choke shutter (2) opens fully. The throttle shutter returns to the idle position when the choke shutter is fully open. Following a starting attempt, the bellows are filled with air from the carburetor box and returned to the neutral position. The air required to pressurize the bellows is drawn in from the carburetor box via a foam filter, a polymer sintered filter, a hose and control valve. The pressurizing process is accompanied by a low whistling noise. The automatic choke uses cylinder temperature as a parameter. Cross section "A" is changed as a function of cylinder temperature. This, in turn, alters the time required to vent the bellows and thus the opening speed of the choke shutter. The regular changes in pressure which occur in the crankcase are used to operate the automatic choke. These pressure waves are fed via a hole in the crankcase and through a port in the cylinder to the control valve (1). The control valve directs the low pressure waves at a predetermined interval to the bellows (2) which contract and thus open the choke shutter (3). The period for which the bellows open the choke shutter depends on cylinder temperature. It varies between 3.5 seconds on a cold engine to approx. 0.1 seconds on a hot engine. A depression is maintained in the bellows while the engine is running, i.e. the bellows are contracted; the choke shutter is open.
A lever mechanism connects the choke shutter to the throttle shutter.
18
915RA023 VA
Carburetors
915RA027 VA
5.3.2
Temperatures/Humidity
5.3.3
Acceleration
Icing can occur in the area of the intake if humidity is high and temperatures are below + 10C (50F). Cause: Air can absorb a certain amount of moisture. The higher the air temperature the greater its capacity to absorb moisture. If the engine draws in damp cold air, pressure and temperature drop and so does the ability to absorb moisture. Moisture condenses on the intake passages, especially in the carburetor. This results in ice forming, which blocks the jets and causes engine running problems. If the air filter is dirty, the air flow rate and pressure in the venturi (Pi) drop. Carburetor heating Some models are equipped with an electric carburetor heating system for operation in extremely cold climates, in which the intake air from around the engine is still too cold.
915RA291 VA
1 3
The thermostatic switch (1) is located on the pump end cover. Power supply takes place automatically via the heating generator.
Accelerator pump Some carburetors are equipped with an accelerator pump. The piston (1) is located in a bore behind the throttle shaft (2) and is held in its neutral position by a spring (3). When the throttle shutter is opened quickly for acceleration, the air is able to adapt rapidly to the new flow conditions because of its low mass. The reaction of the fuel, however, is sluggish by comparison because it first has to be set in motion by the vacuum. This means that a certain time lapses before the fuel has also adapted to the new conditions in the venturi. A flat spot would normally occur because of the over-lean fuel-air mixture. The accelerator pump offsets this effect.
The heating element (1) is positioned on the carburetor mounting studs.
Carburetors
19
915RA029 VA
5.3.4
Dirty Air Filter/ Compensator
3
915RA030 VA
2 1
Pa
Pi 3 2 9 5 Pi 6 Pr
The accelerator pumps piston (1) is located in a bore behind the throttle shaft. The space below the piston is filled with fuel. When the throttle is opened, the control face on the throttle shaft pushes the piston inwards. The fuel below the piston is then injected into the venturi via the valve jet (3). This enriches the fuel-air mixture to ensure a smooth transition without a flat spot during acceleration. When the throttle shaft is turned back, the spring (2) returns the pump piston to its neutral position. A vacuum is created and fresh fuel is drawn from the metering system into the space below the piston.
Compensator 1 2 3 4 5 6 7 8 9 Pa Pi Pr Air filter Carburetor Valve jet Cylinder Metering diaphragm Inlet control valve Fuel pump Fuel tank Compensator Atmospheric pressure Internal pressure Pressure in metering chamber
In this way fuel feed is dependent on the current internal pressure Pi and the amount of air or oxygen that is actually available. The air flow volume is reduced when the air filter is dirty. This causes the pressure Pi at the clean side of the air filter to drop, and also the pressure applied to the outside of the metering diaphragm. The metering diaphragm moves outwards and the inlet control valve reduces the cross section. The flow of fuel is reduced so that the mixture cannot become over-rich.
The compensator connects the clean side of the air filter to the fuel metering system in the carburetor. This means that the pressure applied to the metering diaphragm is identical to the internal pressure Pi in the intake not atmospheric pressure Pa.
20
Carburetors
915RA031 VA
5.4 A carburetor equipped with a compensator therefore keeps the fuel content in the mixture constant at all times, irrespective of air filter contamination. It is no longer necessary to alter the setting of the high speed screw as contamination of the air filter increases. However, engine power drops as a result of the reduction in air volume and can only be restored to normal by cleaning the air filter. There is no need for any further adjustment after cleaning. A conversion from a HD (textile) filter to a standard (wire mesh) filter or vice versa does not necessitate readjustment of the mixture either.
Special Features
Control valve Carburetors that are directly flange-mounted to the cylinder (without a resilient manifold to insulate vibrations) may be equipped with a control valve.
915RA298 VA
Power curve P n a b c Power RPM Clean air filter dirty air filter, with compensator = dirty air filter, without compensator = = = =
This valve (1) opens in response to resonance at a predetermined engine speed. Additional fuel is drawn into the venturi through the passage (2) and the outlet bore. The fuel-air mixture is enriched so that the engine speed cannot increase any further.
Carburetors
21
915RA033 VA
The mixture cannot become overrich. And it is no longer necessary to alter the setting of the high speed screw as contamination of the air filter increases. However, engine power drops due to the reduced quantity of air and fuel. Optimum power can only be restored by cleaning the air filter.
2
915RA034 VA
Speed governor (vane) A torsion spring (1) acts via the governor lever and rod to keep the vane (2) in its neutral position (choke shutter is open). As engine speed increases, the force of the cooling airstrean overcomes spring tension and deflects the governor vane. This movement is transmitted to the choke shutter. When a predetermined limit RPM is reached, the governor vane is deflected to a maximum degree and the choke shutter closes to a point where the richer mixture prevents any further increased in RPM. Note: The cut-off speed can be adjusted by changing the springs preload.
22
Carburetors
6.
Troubleshooting Chart Cause Inlet needle not sealing. Foreign matter in valve seat or cone damaged Inlet control lever sticking on spindle Helical spring not located on nipple of inlet control lever Perforated disc on diaphragm is deformed and presses constantly against inlet control lever Inlet control lever too high (relative to design position) Remedy Remove and clean or replace inlet needle, clean fuel tank, pickup body and fuel line if necessary Free off inlet control lever Remove inlet control lever and refit correctly Fit new metering diaphragm
Condition Carburetor floods; engine stalls
Set inlet control lever flush with top of body or bottom of metering chamber
Poor acceleration
Idle jet "too lean" Main jet "too lean" Inlet control lever too low (relative to design position) Inlet needle sticking to valve seat Connecting bore to atmosphere blocked Diaphragm gasket leaking Metering diaphragm damaged or shrunk
Back off low speed screw slightly Back off high speed screw slightly Set inlet control lever flush with top of body or bottom of metering chamber Remove inlet needle, clean and refit Clean bore Fit new diaphragm gasket Fit new metering diaphragm
Carburetors
23
Condition Engine will not idle, idle speed too high
Cause Throttle shutter opened too wide by idle speed screw Idle speed screw (LD) opened too far Idle speed screw (LA) opened too far Machine leaking
Remedy Reset idle speed screw correctly Adjust idle speed screw correctly Adjust idle speed screw correctly Locate and repair leak
Engine stalls at idle speed
Idle jet bores or ports blocked Idle jet "too rich" Setting of idle speed screw incorrect - throttle shutter completely closed Setting of idle speed screw (LD) incorrect Small plastic plate in valve jet does not close
Clean jet bores and ports with compressed air Screw down low speed screw slightly Set idle speed screw correctly
Set idle speed screw correctly Clean or renew valve jet
Engine speed drops quickly under load - low power
Air filter plugged Tank vent faulty Leak in fuel line between tank and fuel pump Pump diaphragm damaged or fatigued Main jet bores or ports blocked Fuel pickup body dirty Fuel strainers dirty
Clean air filter Clean or replace tank vent if necessary Seal or renew connections and fuel line Fit new pump diaphragm Clean bores and ports Clean pickup body, fit new filter Clean fuel strainers
24
Carburetors
7. 7.1
Servicing Leakage Test If this pressure remains constant, the carburetor is airtight. However, if it drops, the likely causes are: The inlet needle is not sealing (foreign matter in valve seat or sealing cone of inlet needle is damaged or inlet control lever sticking). Check the metering diaphragm for distortion and replace if necessary.
7.2
Cleaning
Carburetor problems are often caused by blocked jets, bores and fuel strainers. Even water droplets, which get into the carburetor with the fuel, can cause trouble. Owing to its high surface tension, water restricts the flow of fuel in the fine jet bores. Water droplets may freeze in winter and completely block fuel passages. To clean the carburetor, strip it down and remove the adjusting screws, jets and inlet needle. Use a brush or a clean leather cloth and fresh fuel to clean the carburetor body. Then blow out all ports and jets with compressed air. Warning: Never use needles, wires or similar tools or fibrous cloths for cleaning the carburetor or jets.
The carburetor can be tested for leaks with the carburetor and crankcase tester (1) 1106 850 2905. - Check the tester for leaks. The following test values refer to carburetors that have been flushed with fuel and have moist diaphragms. Dry carburetors must not be subjected to pressures of more than 0.35 bar (5 psi).
In these cases the carburetor must be serviced. - After completing the test, open the vent screw and remove the fuel line from the intake fitting.
Flush dry carburetors with fuel

before starting the test. Carburetors can only seal properly when the fuel passages and all sealing points are wetted with fuel. The pressure applied during the test must not exceed 1 bar (14.5 psi). If higher pressures are applied, the control valve will open and allow the pressure to enter the metering chamber and possibly over-stretch the metering diaphragm.
Push fuel line (2) 1110 141 8600

with nipple (3) 0000 855 9200 onto the carburetors intake fitting.
Connect testers pressure hose

to nipple.
Close vent screw (4) on the

rubber bulb (5) and pump air into the carburetor until the pressure gauge shows a reading of approx. 0.8 bar (11.6 psi).
Carburetors
25
7.3
Pump Diaphragm - Inspect diaphragm and gasket and replace if necessary. Note: The diaphragm and the inlet and outlet valves are exposed to continuous alternating stresses and the material eventually shows signs of fatigue. The diaphragm distorts and swells and has to be replaced.
7.4
Metering Diaphragm
Take out the screws. Remove the end cover.
915RA036 VA
Take out the screws.

- Remove the end cover. - For carburetors with manual fuel pump see 7.9.
3 1 2
915RA037 VA
Remove the gasket (1) and

pump diaphragm (2) from the end cover or carburetor body. Note: If the gasket and diaphragm are stuck, remove them carefully.
Place the gasket (1) on the end

cover (2).
915RA039 VA
Remove metering diaphragm

and gasket from carburetor body or end cover. Note: If the gasket and diaphragm are stuck, remove them carefully.
Wet the pump diaphragm (3)

with fuel and place it on the gasket. - Fit the end cover on the carburetor body. Note: Pump diaphragm, gasket and end cover are held in position by the integrally cast pegs on the end cover. - Insert screw(s) and tighten down securely.
915RA038 VA
Carefully separate the

diaphragm and gasket.

diaphragm and gasket.
26
Carburetors
7.5 - Inspect diaphragm and gasket and replace if necessary. Note: The diaphragm is exposed to continuous alternating stresses and the material eventually shows signs of fatigue. The diaphragm distorts and swells and has to be replaced.
2 1
Inlet Needle
Fit pump diaphragm so that

perforated plate (1) points towards the inlet control lever (2).
915RA045 VA
- Remove metering diaphragm see 7.4.
Take out the screw.

- Remove inlet control lever with spindle or plate with inlet control lever and gasket. Pull out the inlet needle.
1
915RA043 VA 915RA046 VA
Place gasket on carburetor body.
If the peg (1) is on the end cover,

place the metering diaphragm (2) and gasket (3) on the end cover. - Fit end cover in position.
915RA044 VA
Place metering diaphragm on

gasket. Note: Gasket and metering diaphragm are held in position by the integrally cast pegs. Carburetors
915RA047 VA
Install end cover with connector. Fit screws and tighten down
securely.
Carburetors with compensator:
If there is an annular indentation

on the sealing cone of the inlet needle, it will be necessary to replace the inlet needle because it will no longer seal properly.
27
915RA048 VA
7.6
Main Jet
4 3 1
If the plate of the check valve in the main jet no longer moves freely, install a new main jet. - Remove metering diaphragm see 7.4.
915RA058 VA
Fit the inlet needle (1). Fit helical spring (2) in the blind
hole.
915RA051 VA
Install the main jet exactly

vertical in the bore. Press it home until it is flush with the bottom of the metering chamber.
Insert spindle (3) in the inlet

control lever (4). - Engage clevis of inlet control lever in annular groove on the head of the inlet needle. - Press down the inlet control lever and secure it with the screw.
915RA056 VA
Note: Make sure that the helical spring locates on the control levers nipple. - Check easy action of the inlet control lever. Important: The top of the inlet control lever must be level with the bottom of the metering chamber (1) or the top face of the carburetor body (2).
Use a suitable pin punch to

press the main jet out of its seat in the direction of the venturi.
915RA054 VA
- If this is not the case, the inlet control lever is bent and must be replaced. - Install metering diaphragm see 7.4. 28
Use a screwdriver to push the

valve jet out of its seat from inside the venturi. - Wash the main jet in white spirit. Carburetors
WS-26A carburetor:
915RA057 VA
7.7
Full-Load Fixed Jet/ Part-Load Fixed Jet
7.8
Control Valve
1 2 2 1
915RA060 VA
915RA062 VA
- Remove metering diaphragm see 7.4. Note: The part-load fixed jet (1) cannot be replaced, it can only be blown clear with compressed air.
HD-5 carburetor: Use a scriber to remove the retaining ring (1).
Tap the carburetor body against

a wooden base to remove the full-load fixed jet (2) and 0-ring (3). - Wash full-load fixed jet in white spirit and blow out with compressed air. Note: Replace damaged full-load fixed jet. - Install full-load fixed jet exactly vertical in the bore. Press it home until it is flush with the bottom of the metering chamber. HD-5 carburetor: - Fit a new 0-ring in the bore. - Press home the fixed jet (flat side up) as far as stop and secure in position with retaining ring. - Install metering diaphragm see 7.4.
WT-227E and WT-264 carburetors: - Remove the manual fuel pump see 7.9.
Unscrew the control valve (1). Take the copper washer (2) out
of the bore (3). - Fit a new copper washer in the bore for the control valve. - Screw in new control valve about 2 full turns. - Coat the thread that still projects from the carburetor body with Loctite - see 8.2. - Carefully screw home control valve as far as stop and tighten down to 4 Nm (3.0 lbf.ft).
Use a pin punch to press the fullload fixed jet (2) out of its seat in the direction of the venturi.
Unscrew the full-load fixed jet.
HS-262B carburetor:
Carburetors
915RA061 VA
29
915RA063 VA
7.9
Manual Fuel Pump
7.10
Check Valve
1 2
915RA064 VA
915RA067 VA
Take out screws (1). Remove end cover with pump

bulb (2).
Take valve out of flange.

- Check valve and replace if necessary. Note: If the circuit for filling the metering chamber is malfunctioning, if the valve is dirty, distorted or damaged, install a new valve.
- Remove metering diaphragm see 7.4.
Fit a 2.5x13 mm self-tapping

screw in the check valves bore and use it to pull out the check valve.
915RA065 VA
Remove the pump bulb.
Use a 4 mm (approx. 5/32") pin

punch to press the check valve squarely into the metering chamber as far as stop. - Install metering diaphragm see 7.4.
915RA066 VA
Remove the flange.
Check metering diaphragm and

sealing ring and replace if necessary - see 7.4. Assemble in the reverse sequence.
30
915RA068 VA
Carburetors
915RA070 VA
915RA069 VA
7.11
Carburetor Body - Wash the carburetor body in fresh white spirit and blow all ports and bores clear with compressed air. - To replace the carburetor body, remove the throttle shaft and, if fitted, the choke shaft - see 7.12 and 7.13. - Place the new sealing plug or plate in the bore with its convex side facing up. - Use a large pin punch to apply light pressure until the sealing plug or plate is flat. - Secure new sealing plate or plug with Loctite - see 8.2. (Apply Loctite to gap between carburetor body and sealing plate or plug.) Assemble all other parts in the reverse sequence.
- Remove pump diaphragm see 7.3. - Remove inlet needle - see 7.5. - Remove valve jet - see 7.6.
915RA075 VA
- Remove full-load fixed jet, if fitted - see 7.7. - Remove check valve, if fitted see 7.10. Caution: Idle speed screw (LD) has a left-hand thread.
Use a scriber to pry out fuel

strainer and then clean it. Important: Always replace a damaged fuel strainer.
915RA071 VA
Use a pin punch to press the

center of the sealing plug (1) or sealing plate (2) until it buckles and can be taken out. Important: The sealing plug or sealing plate is destroyed during removal.
2 1
Take out the high speed screw

(1), low speed screw (2) and, if fitted, the idle speed screw (3).
Carburetors
915RA074 VA
31
7.12
Throttle Shaft
915RA077 VA
- For carburetors with automatic choke see 7.15.1.
On some carburetors, remove

the screw from the lever. - Remove the lever.
915RA080 VA
Carefully withdraw the throttle

shaft. - Check for excessive play which may be a source of secondary air. - For carburetors with accelerator pump see 7.14.
Take out the screw.

- Remove the throttle shutter or pull it out of the throttle shaft.
2 1
- On some carburetors it is necessary to remove the pump end cover before withdrawing the throttle shaft - see 7.3.
915RA078 VA
On C1Q-S11G, detach torsion

spring (1) from groove in throttle shaft (2).
Remove spacer sleeve.
915RA079 VA
915RA085 VA
915RA081 VA
Remove the E-clip.

- Take off the washer, if fitted.
On some carburetors, take out

the screw (1).
Pull off the torsion spring.
Pull the clip (2) off the throttle

shaft.
32
Carburetors
915RA087 VA
915RA086 VA
2 1 1 2
915RA088 VA 915RA090 VA 915RA093 VA
On throttle shafts with a slotted

pin (1), remove the E-clip (2).
On C1Q-S11G, attach torsion

spring (1) to groove in throttle shaft (2).
On WT-253, fit lever (1) so that it

points towards intake fitting (2).
Take slotted pin out of the

lever (3).
4
3 2
3
1
2
915RA089 VA
After pushing home the throttle

shaft, check that torsion spring is correctly positioned. Note: The illustration shows the WT-227F carburetor. The position of the torsion springs on other carburetors is similar. - Install throttle shutter so that its entire circumference locates against the wall of the venturi. - Coat screw with Loctite, see 8.2, and tighten down securely. - Fit E-clip or clip in the groove. - Secure clip with screw.
On WT-230, push spacer sleeve

(1) into position.
915RA091 VA
On C1Q-SK6, fit lever (1) so that

slotted pin (2) points towards the metering chamber end cover (3).
Fit lever (2) so that the slotted

pin (3) points towards metering chamber end cover (4).
On HD-3A, fit the spacer

sleeve (1).
Fit lever (2) so that slotted pin (3)

points towards intake fitting (4).
Carburetors
915RA092 VA
33
915RA094 VA
7.13
Choke Shaft
915RA099 VA
915RA102 VA
- For carburetors with automatic choke see 7.15.1.
Remove the E-clip, if fitted.
Remove the torsion spring.
Pull off the lever, if fitted.
2 1
915RA078 VA
915RA103 VA
On C1Q-S11G, detach torsion

spring (1) from groove in throttle shaft (2).
Withdraw the choke shaft with

torsion spring.
- Fit the torsion spring.
After fitting the choke shaft,

check that the torsion spring is correctly positioned.
915RA101 VA
Take out the screw.

- Remove the choke shutter or pull it out of the choke shaft.
Carefully withdraw choke shaft

without torsion spring so that the ball does not pop out and be lost. - Take out the ball and spring.
34
915RA104 VA
Carburetors
915RA106 VA
915RA105 VA
7.14
Accelerator Pump
2 1
2 2 1 1
3
915RA107 VA
915RA090 VA
On choke shafts without torsion

spring, fit the spring (1) and ball (2).
On C1Q-S11G, attach torsion

spring (1) to groove in throttle shaft (2). - Refit the lever, if removed.
- Remove the throttle shaft see 7.12.
Push home the choke shaft until

the ball engages the groove (3). - Install choke shutter so that its entire circumference locates against the wall of the venturi. - Fit screw with Loctite, see 8.2, and tighten down securely. - On choke shafts with torsion spring, fit the E-clip.
Knock the pump piston (1) and

spring (2) out of the bore (3).
Take the sealing ring (4) off the

pump piston. - Inspect pump piston and spring and replace if necessary.
Fit new sealing ring (4) in groove

of pump piston (1).
Place spring (2) in the bore (3). Fit pump piston (1) in the bore,
closed end facing outward. - Install throttle shaft - see 7.12. - Press down the pump piston so that throttle shaft can be pushed home.
Carburetors
35
915RA109 VA
2 4 1
7.15
Lever Mechanism on Carburetors with Automatic Choke

H G B
915RA110 VA 915RA112 VA
Removal:
Fit the torsion spring "D" on the

throttle shaft "E" so that its bent end points away from the carburetor.
Fit the bell crank "G" (with flat

face pointing to lever "B") over the choke shaft so that the pin on lever "B" is between the arms of bell crank "G".
Carefully pry bell crank "G" and

lever "H" off the shafts. - Remove the lever system from the shafts. - Take the torsion spring off the throttle shaft. Installation: Note: Bell crank "G" and lever "H" have to be pressed onto the shafts. To do this, clamp the carburetor body in position so that the pressure used to install the levers is transmitted to the carburetor body via a short part of the shaft and the retaining ring. This procedure ensures that the shaft is not loaded beyond its buckling strength.
Rotate bell crank counterclockwise until its right arm butts against the pin on lever "B".
B
915RA113 VA
Push lever "A" on to the throttle

shaft and, at the same time, lever "B" on to the choke shaft.
B B A C
915RA111 VA 915RA114 VA 915RA116 VA
Carefully push the link "C" into

position to connect levers "A" and "B".
Rotate lever "B" on choke shaft

counterclockwise as far as stop.
With the bell crank in this position, carefully press it on to the choke shaft. Caution: Take care not to bend the choke shaft.
36
Carburetors
915RA115 VA
LA
H A
915RA117 VA
- Open the choke shutter by slowly turning the right-hand end of the choke shaft. The throttle shutter must jump to the closed position just before the choke shutter is fully open.
915RA119 VA
Note: This is accompanied by a definite clicking sound.
Turn the idle speed screw "LA"

counterclockwise until the throttle shaft is clear of the taper on the idle speed screw.
Fit lever "H" on the throttle shaft

and rotate it counterclockwise until it butts against the pin on lever "A".
915RA118 VA
915RA120 VA
Open the choke shutter "I" and

hold it steady in that position.
Press lever "H" on to the throttle

shaft. Caution: Take care not to bend the throttle shaft.
Attach bent end of torsion spring

to pin on lever "H".
Swing lever "A" counterclockwise as far as stop. Important: The choke shutter must be held open for the next two operations.
37
915RA059 VA
Installed positions of levers:
Push the straight end of the

torsion spring between the carburetor body and pin on lever "A" and locate it behind the levers pin.
In the idle position the choke

shutter must be closed and the throttle shutter at an angle of 37 degrees to the carburetor mounting face. Carburetors
37
915RA122 VA
915RA121 VA
7.15.1 Throttle Shaft/ Choke Shaft - Remove lever mechanism see 7.15. - Remove the throttle shaft see 7.12.
B
915RA123 VA
7.16
HL-324A/HL-327D/LA-S8A Carburetors
- Remove the choke shutter see 7.13.
Checking installed position of torsion spring: - Open throttle and choke shutters simultaneously and hold them steady.
Slip the grommet, if fitted, off the

carburetor adjusting screws.
The torsion spring must move

levers "A" and "B" into the positions shown in the illustration.
3 2
1
915RA124 VA
915RA127 VA
- Ease the E-clip off the choke shaft.
Remove screws (1) from intake

manifold, if fitted.
Pull out the choke shaft.
Remove the intake manifold (2)

and gasket (3).
1 2 3 4
915RA125 VA 915RA128 VA
Remove torsion spring (1),

choke lever (2) and torsion spring (3) from the choke shaft (4). Install in the reverse sequence. 38
- Mark position of intake fitting relative to fuel pump body.
Take out the screw.

- Remove the end cover. Carburetors
915RA126 VA
Note: The throttle shaft is longer than on carburetors without automatic choke.
915RA129 VA
915RA132 VA
Take out the gasket (1) and fuel

strainer (2). - Clean the fuel strainer.

diaphragm and gasket. - Inspect diaphragm and gasket and replace if necessary. Note: The diaphragm and the inlet and outlet valves are exposed to continuous alternating stresses and the material eventually shows signs of fatigue. The diaphragm distorts and swells and has to be replaced.
Remove the metering diaphragm

and gasket from the carburetor body or diaphragm cover. Note: If the gasket and diaphragm are stuck, remove them carefully.
915RA130 VA
Take out the screws.

- Remove fuel pump body.

diaphragm and gasket. - Inspect diaphragm and gasket and replace if necessary. Note: The diaphragm is exposed to continuous alternating stresses and the material eventually shows signs of fatigue. The diaphragm distorts and swells and has to be replaced.
Remove pump diaphragm and

gasket. Note: If diaphragm and gasket are stuck, remove them carefully.
Remove diaphragm cover.
Carburetors
915RA133 VA
39
915RA135 VA
915RA134 VA
915RA136 VA
915RA139 VA
Take out the screw.
Use a thin-walled 8mm socket

wrench to unscrew the valve body. - Take out the gasket.
On HL-327D, unscrew the

control valve. - Take the copper washer out of the bore.
1 4 2 3
915RA137 VA
915RA140 VA
Remove inlet control lever (1)

with spindle (2).
Unscrew the high speed screw

(1), low speed screw (2) and idle speed screw (3).
Use a 5 mm (approx. 3/16") pin

punch to press the valve jet out of its seat in the direction of the venturi. - Wash valve jet in white spirit.
Remove the helical spring (3). Pull out the inlet needle (4).
915RA138 VA
915RA141 VA
1 2

Remove washer (1) and 0-ring

(2) from the carburetor body or the adjusting screws.
Apply a 3 mm (1/8") pin punch to

the center of the sealing plug and press down until it buckles and can be taken out.
40
Carburetors
915RA144 VA
915RA143 VA
915RA142 VA
- Wash the carburetor body and all serviceable parts in fresh white spirit and blow clear with compressed air, paying special attention to the bores and ports. - To replace the carburetor body, remove the throttle shaft and choke shaft see 7.16.1 and 7.16.2. - Place the new sealing plug in the bore with its convex side facing up. - Use a 8 mm (5/16") pin punch to apply light pressure until the sealing plug is flat. - Secure new sealing plug with Loctite - see 8.2. (Apply Loctite to gap between carburetor body and sealing plug.)
2 1
915RA146 VA 915RA148 VA
Fit a new gasket (1). Fit valve body (2) and tighten
down securely.
Important: The top of the inlet control lever must be level with the bottom of the metering chamber. - If this is not the case, the inlet control lever is bent and must be replaced.
2
915RA149 VA
Insert inlet needle (1). Fit helical spring (2) in blind hole. Fit spindle (3) in inlet control
lever (4). - Engage clevis of inlet control lever in annular groove on the head of the inlet needle. - Press down the inlet control lever and secure it with the screw. Note: Make sure that the helical spring locates on the control levers nipple. - Check easy action of the inlet control lever.
Fit the gasket and metering

diaphragm (1). Note: They are held in position by the integrally cast pegs (2) on the carburetor body.
1 2 3
915RA145 VA
Install the valve jet exactly

vertical in the bore. Press it home until it is flush with the bottom of the metering chamber.
On the LA-S8A, the locating

pegs (1) are on the diaphragm cover. Therefore, the metering diaphragm (2) and gasket (3) should be fitted on the diaphragm cover. 41
Carburetors
915RA150 VA
- Fit fuel strainer and gasket in the fuel pump body. Note: Always replace a damaged fuel strainer. - Fit the end cover.
915RA151 VA
- Screw in new control valve about 2 full turns. - Coat the thread that still projects from the carburetor body with Loctite - see 8.2. - Screw home control valve and tighten down to 4 Nm (3.0 lbf.ft).
- Line up the intake fitting according to mark made prior to disassembly. - Fit screw and tighten down securely.
Fit the diaphragm cover.
3 2
1
915RA152 VA 915RA154 VA
Fit the gasket (1) and pump

diaphragm (2). Note: The gasket and pump diaphragm are held in position by the integrally cast pegs on the diaphragm cover.
Slip spring (1), washer (2) and

new 0-ring (3) over high speed and low speed screws. - Carefully screw high speed and low speed screws down onto their seats and then back them off one full turn. - Fit idle speed screw. - On HL-327D, fit new copper washer in bore for control valve.
Fit the fuel pump body.

- Fit screws and tighten them down alternately in a diagonal pattern.
42
915RA153 VA
Carburetors
7.16.1 Throttle Shaft - Install throttle shutter so that its entire circumference locates against the wall of the venturi. - Fit screw with Loctite, see 8.2, and tighten down securely. - Fit clip in the groove.
915RA162 VA 915RA165 VA
- Insert screw and tighten down firmly. - Install cable guide, if fitted.
Take out the screw.

- Remove lever or throttle lever.
Remove screws (1) from cable

guide (2), if fitted. - Lift away cable guide.
1
915RA163 VA 915RA166 VA
Take out the screw.

- Pull the throttle shutter out of the throttle shaft.
Pull out the throttle shaft. Remove the torsion spring (1).
On HL-327D, fit lever so that the

slotted pin (1) points towards diaphragm cover (2). - Insert screw and tighten down firmly.
3
915RA164 VA 915RA167 VA
2 1
Take out the screw (1). Pull off the clip (2).
After pushing home the throttle

shaft, check that torsion spring is correctly positioned.
On LA-S8A and HL324A, fit

throttle lever (1) so that round end (2) point downwards to connecting flange (3). - Insert screw and tighten down firmly.
Carburetors
43
915RA169 VA
915RA168 VA
7.16.2
Choke Shaft
2
1 2
2
915RA155 VA
915RA158 VA
- Remove the intake manifold, if fitted - see 7.16.
On HL-327D and HL-324A, take

out the screw (1).
Note: On HL-327D, fit the spring (1) and ball (2).
Ease the E-clip (1) off the

governor rod (2), if fitted. - Remove the governor rod.
Pull off the clip (2).
Push home the choke shaft until

the ball engages the groove (3). - Fit clip in groove in choke shaft. - Secure clip with screw.
915RA156 VA
On LA-S8A and HL327D, take

out the screw (1).
Withdraw the choke shaft.

Note: On HL-327D, carefully withdraw choke shaft so that the ball does not pop out and be lost. - Slide choke shaft into the carburetor from the adjusting screw side.
Remove the governor lever (2).
915RA157 VA
915RA159 VA
Take out the screw.

- Pull the choke shutter out of the choke shaft.
On LA-S8A and HL327D, rotate

choke shaft so that slot (1) is horizontal and the flat side (2) points down.
44
Carburetors
915RA161 VA
915RA160 VA
7.17
WYL-63 / WYL-73 Rotary Valve Carburetors

1 1
2 1
915RA055 VA
1
915RA192 VA 915RA191 VA
On HL-324A, rotate choke shaft

so that the pin (1) points forward.
Take out the screws (1). Remove the end cover (2) with
cap.
Take valve out of flange.

- Check valve and replace if necessary. Note: If the circuit for filling the metering chamber is malfunctioning, if the valve is dirty, distorted or damaged, install a new valve.
Fit the choke shutter so that the

hole (2) points forward and the indentations (3) face the end cover. - Fit screw with Loctite, see 8.2, and tighten down securely.
Pull out the cap.
- On LA-S8A and HL327D, close the choke shutter.

3
915RA171 VA
915RA194 VA
915RA193 VA
Fit governor lever (1) so that the

pin (2) lines up with the center of the high speed screw (3). - Fit screw and tighten down securely. Carburetors
Remove the flange.
Remove metering diaphragm

and gasket. Note: If the gasket and diaphragm are stuck, remove them carefully.
45
915RA196 VA
3
915RA195 VA
2
915RA197 VA
915RA201 VA

diaphragm and gasket. - Inspect diaphragm and replace if necessary. Note: The diaphragm is exposed to continuous alternating stresses and the material eventually shows signs of fatigue. The diaphragm distorts and swells and has to be replaced.
Remove the screw (1). Remove inlet control lever (2)

with spindle (3) and spring.
Remove gasket and pump

diaphragm. Note: If gasket and diaphragm are stuck, remove them carefully.
915RA199 VA
- Pull out the inlet needle.

diaphragm and gasket. - Inspect diaphragm and replace if necessary. Note: The diaphragm is exposed to continuous alternating stresses and the material eventually shows signs of fatigue. The diaphragm distorts and swells and has to be replaced.

915RA198 VA
Remove pump housing.
Use a scriber to pry out fuel

strainer and then clean it. Important: Always replace a damaged fuel strainer.
46
915RA200 VA
Carburetors
915RA202 VA
2 3
- Insert screws and tighten down securely.
915RA203 VA
Remove the spring.
If necessary, pry off the retaining

ring (1) and pull out the slotted pin (2) with washer (3).
Take out the idle speed

screw (4). - Wash the carburetor body and all serviceable parts in fresh white spirit and blow clear with compressed air, paying special attention to the bores and ports.
1
40
915RA206 VA
915RA204 VA
Use a scriber to carefully ease

the main jet out of its seat. - Remove the sealing ring.
Slip 0-ring (1) over the main

jet (2). - Press main jet into carburetor seat as far as stop. Note: Check size of main jet (number on main jet): 40 = WYL-63 36 = WYL-73
1
915RA205 VA
Take out the screws (1). Pull out the control valve (2).
Install the control valve so that

the idle speed screw (1) points to the left - viewed from stub (2).
Carburetors
915RA207 VA
47
915RA208 VA
Insert spindle (3) in the inlet

control lever (4). - Engage clevis of inlet control lever in annular groove on the head of the inlet needle.
915RA213 VA
915RA209 VA
- Press down the inlet control lever and secure it with the screw. Note: Make sure that the helical spring locates on the control levers nipple.
Fit the spring (1). Fit a new gasket (2).
Fit the pump housing.
915RA212 VA
915RA210 VA
Place pump diaphragm on the

gasket. Note: Gasket and pump diaphragm are held in place by the integrally cast pegs.
Important: Measure distance "a" between upper edge of inlet control lever and pump housing. It must be 1.5 mm (0.06"). - If the distance more or less than specified, the inlet control lever is bent and must be replaced.
Fit a new gasket.
3 1 2
915RA211 VA
Fit the inlet needle (1). Fit helical spring (2) in the blind
hole.
Fit diaphragm on the gasket

so that perforated plate points towards the inlet control.
48
Carburetors
915RA215 VA
915RA214 VA
Note: Gasket und pump diaphragm are held in place by the integrally cast pegs.
- Insert screws and tighten down securely. Adjusting idle speed and idle mixture Note: If either the carburetor or the control valve has been replaced, it will be necessary to adjust idle jet needle in the control valve.
- From that position, turn the idle jet needle one eight turn counter clockwise to reduce engine speed by 200 - 500 rpm. - Remove the screwdriver and once more set idle speed to 3100 200 rpm with the idle speed screw. Note: Adjustment of maximum engine speed is not necessary because it is determined by the main jet. - Fit plug in the control valve.
- Insert the valve in the flange.
Set the idle speed to 3100

200 rpm with the idle speed screw (1). Note: Use a tachometer.
Fit the flange in position.
Pull plug (2) out of the control

valve. - Start the engine.
Use a small screwdriver (3) to

rotate the idle jet needle (4) clockwise or counterclockwise until maximum engine speed is reached.
915RA216 VA
- Fit the cap in the end cover.
Fit the end cover.
Carburetors
915RA217 VA
915RA194 VA
49
7.18 7.18.1
Standard Setting on Walbro Carburetors Fixed Jet Carburetors
WT-283B, WT-323, WT-325A, WT-326C, WT-360, WT-396, WT-403A, WT-493, WT-498A, WT-503 These carburetors have a fixed jet in place of a high speed adjusting screw (H screw). Maximum engine speed is preset and no longer adjustable. It is only possible to correct idling speed within certain limits. These carburetors guarantee an optimum fuel-air mixture in all operating conditions.
Carefully screw down the low

speed screw (L) clockwise until it is against its seat. Then back it off one full turn counterclockwise. - Check chain tension. - Check air filter and clean if necessary. - Check spark arresting screen and clean or replace if necessary. - Start the engine and allow it to warm up.
Note: Turn screws very slowly and carefully - even slight movements produce a noticeable change in engine running behavior.
Engine stops while idling: - Check standard setting. - Turn idle speed screw clockwise until the chain begins to run then turn it back one quarter turn. Chain runs while engine is idling: - Check standard setting. - Turn the idle speed screw counterclockwise until the chain stops running - and then turn it about another quarter turn in the same direction. Erratic idling behavior, poor acceleration even though low speed screw (L) is one turn open: - Idle setting is too lean. - Turn the low speed screw (L) counterclockwise until the engine runs and accelerates smoothly.
915RA294 VA
LA
Standard setting To readjust the carburetor, start with the standard setting.
Adjusting idle speed
A correction at the low speed

screw (L) usually necessitates a change in the setting of the idle speed screw (LA). Carburetors
50
915RA295 VA
7.18.2
Carburetors with Limiter Caps Note: Limiter caps are damaged during removal. They must not be used again. - If necessary, take out the low speed and high speed screws. One brushcutters: - Mount STIHL Autocut or Polymatic cutting head. - Adjust line length so that it extends as far as limiter blade on deflector.
HD-13A, HD-16, HD-17, HD-18A, HD-21A, HD-22, WY-69, WT-329, WT-330, WT-367, WT-393, WT-489, WT-492, WJ-69
915RA293 VA
Turn the cap to line up the lug

with the slot.
Carefully screw high speed

screw (1) and low speed screw (2) with sealing rings (3) down onto their seats. - Refer to flow chart for carburetor adjustment - see 7.21. Preparations - Check air filter and clean if necessary. - Inspect spark arresting screen and clean or replace as necessary.
915RA218 VA
915RA219 VA
Basic setting (all models)
Starting with the adjusting

screws (H) and (L) firmly against their seats, open them by the number of turns specified below. Model BR 320 L BR 320, 400 FC 44 FS 36, 40, 44 FS 72, 74, 76 FS 88 FS 550 HS 72, 74, 76 BG 72 MS 044, 046 MS 029, 039 MS 066 H 1.5 2 4 1.5 1 1 1 1 L 4 2.5 4 1 1 1 1
On blowers: - Fit blower tubes and nozzles. On hedge trimmers: - Clean and oil cutting blades.
Screw puller (1) 5910 890 4500

into cap counterclockwise until it comes off the the head of the adjusting screw (left-hand thread).
Carburetors
51
915RA225 VA
- This enables the mixture to be made leaner, if necessary, for operation at high altitudes and prevents it being enriched beyond the emission limits specified by EPA.
Model BR 320 L BR 320, 400 FC 44 FS 36, 40, 44 FS 72, 74, 76 FS 88 FS 550 HS 72, 74, 76 BG 72
RPM 3100 3100 3100 3100 2800
MS 029/039 and MS 044/046 Fitting limiter caps
Insert the new caps in the bores,

making sure the lugs are correctly positioned (arrows).
Push the caps on to the adjusting screws until they are flush with the insert (1). Adjusting idle speed Note: Use a tachometer.
BR 320 L, BR 320, 400, FC 44, FS 36, 40, 44, FS 72, 74, 76, FS 88, FS 550, HS 72, 74, 76, BG 72
Full-load setting
915RA228 VA
(029/039) or 2500 rpm (044/046) with the idle speed screw (2). Adjusting idle speed
On blowers:
- Refer to flow chart for carburetor adjustment - see 7.21.
Running at full load, turn high

speed screw (H) slowly clockwise until maximum engine speed is reached.
Use the low speed screw (L) to

set maximum idle speed.
Turn low speed screw (L)

counterclockwise until engine speed drops about 300 rpm.
Turn high speed screw (H)

Use the idle speed screw (LA)

H 270 L 270
915RA227 VA
to set engine speed as specified below.
Corrections are now possible

only within a range of 270 degrees because the integrally molded stops in the bores limit any further adjustment. 52 Carburetors
915RA229 VA
Set idle speed to 2800 rpm
Checking running behavior - Open the throttle several times to check that engine accelerates smoothly. - Engine must run uniformly at idle speed.
915RA229 VA
90
On brushcutters (with cutting head and deflector fitted):

only within a range of 90 degrees because the integrally molded stops in the bores limit any further adjustment. - This enables the mixture to be made leaner, if necessary, for operation at high altitudes and prevents it being enriched beyond the emission limits specified by EPA.

speed screw (H) slowly clockwise until no further increase in engine speed is achieved within a speed range of 6500 8500 rpm. Note: If the required speed range is not reached, adjust the length of the nylon line until it is.
2 1
915RA230 VA

counterclockwise until engine speed drops about 100 rpm. On edgers:

speed screw (H) slowly clockwise until engine speed of 9000 rpm is exceeded.
Fitting limiter caps
Fit cap (1) on adjusting screw so

that the integrally molded lug (2) locates in the gate (3) in the bore. - Push caps into bores until they are flush with the carburetor body.

counterclockwise until an engine speed of about 8000 rpm is reached.
Turn high speed screw (H) one

half turn clockwise (leaner).
Carburetors
53
915RA231 VA
7.19 7.19.1
Standard Setting on Zama Carburetors Fixed Jet Carburetors
C1Q-S30C, C1Q-S37A, C1Q-S41, C1Q-S42, C1Q-S34B, C1Q-S36B These carburetors have a fixed jet in place of a high speed adjusting screw (H screw). C1Q-S34B and C1Q-S36B carburetors (FS 300...450) have no low speed screw (L screw). Maximum engine speed is preset and no longer adjustable. It is only possible to correct idling speed within certain limits. These carburetors guarantee an optimum fuel-air mixture in all operating conditions.

speed screw (L) clockwise until it is against its seat. Then back it off one full turn counterclockwise. - Mount an approved cutting tool. If cutting head is fitted: - Adjust nylon line to correct length. Each line must extend as far as limiter blade on the deflector. - On HS 75, 80, 85, check cutting blades and clean if necessary (they must be clean, move freely and not be warped). - Check air filter and clean if necessary. - Inspect spark arresting screen and clean or replace as necessary. - Start the engine and allow it to warm up.
Cutting head rotates while engine is idling: - Check standard setting. - Turn the idle speed screw (LA) counterclockwise until the cutting head stops rotating - and then turn it about another half turn in the same direction. Engine accelerates poorly or stops after idling for long period: - Check standard setting. - Turn low speed screw (L) one quarter turn counterclockwise. - Use idle speed screw (LA) to set engine speed to 2800 rpm, repeat both settings if necessary. Engine stops while being swung, during transition from full load to idle or idles erratically: - Check standard setting. - Turn low speed screw (L) one eight turn clockwise. - Use idle speed screw (LA) to set engine speed to 2800 rpm, repeat both settings if necessary.
Adjusting idle speed Engine stops while idling: - Check standard setting.
Turn idle speed screw (LA)

clockwise until the cutting head begins to rotate - then turn it back one half turn.
On HS 75, 80, 85, use the idle

speed screw (LA) to set idle speed to 2800 rpm.
Standard setting To readjust the carburetor, start with the standard setting.
54
915RA296 VA
Carburetors
7.19.2 HS 75, 80, 85 Cutting blades run while engine is idling: - Use idle speed screw (LA) to set engine speed to 2800 rpm. - Turn idle speed screw (LA) counterclockwise until cutting blades stop running and then turn it about another half turn in the same direction. Cutting tool rotates when engine is idling: - Turn idle speed screw (LD) counterclockwise until cutting tool stops rotating and then turn it about another full turn in the same direction.
Carburetors with Limiter Caps
C1Q-SK7, C3A-S39A
FS 300...450
C1Q-SK7
+ LD -
915RA297 VA
Set idle speed correctly with

the idle speed screw (LD). The cutting tool must not rotate. Adjusting idle speed Engine stops while idling: - Turn the idle speed screw (LD) clockwise until the engine runs smoothly. The cutting tool must not rotate.
Pull the cap off the adjusting

screw. Note: Limiter caps are damaged during removal. They must not be used again.
3 2
3 2
If necessary, take out the adjusting screws (1) with washers (2) and springs (3).
Carburetors
55
915RA233 VA
915RA232 VA
Turn low speed screw (L)

H L
Use the idle speed screw (LD) to

set engine speed to 2800 rpm.
915RA236 VA
Note: Use screwdriver (1) 5910 890 2305 or 0000 890 2300 to install the adjusting screws and adjust the carburetor.
Basic setting Note: Use a tachometer.

screws (H) and (L) firmly against their seats, open each screw two full turns. - Start the engine. - Carry out full-load setting. Warning! Observe safety precautions - see 1.
915RA235 VA
Full-load setting
32
Installation

speed screw (H) slowly clockwise until no further increase in engine speed is achieved within a speed range of 6500 8500 rpm. Adjusting idle speed Note: If the required speed range is not reached, adjust the length of the nylon line until it is.
LD L
Carefully screw the adjusting

screw (1) with washer (2) and spring (3) down onto its seat. - Refer to flow chart for carburetor adjustment - see 7.21. Preparations - Check air filter and clean if necessary. - Inspect spark arresting screen and clean or replace as necessary. - Mount STIHL Autocut or Polymatic cutting head. - Adjust line length so that it extends as far as limiter blade on deflector.
Use the low speed screw (L) to

set the maximum idle speed.
56
915RA237 VA
Carburetors
915RA238 VA
90
d
H
b c
915RA238 VA
915RA240 VA
Turn high speed screw (H) counterclockwise until engine speed drops about 100 rpm. Checking running behavior - Open the throttle several times to check that engine accelerates smoothly. - Engine must run uniformly at idle speed.
Use a standard commercial

screwdriver to make up an installing tool to push the caps on to the adjusting screws. a = 75.0 mm b= 5.6 mm c= 1.0 mm d= 1.5 mm e= 4.0 mm
The integrally molded stop

operates when the cap is fixed in position.
The stop limits the adjustment

range of the screw to 90 degrees. - However, it allows a correction to the setting if the engine runs unsatisfactorily after extreme changes in altitude, humidity or outside temperature. - Emissions always remain below the limits set by CARB.
Fitting limiter caps - Shut off the engine. Identification of caps: High speed screw = red Low speed screw = white
2
2
915RA239 VA
Slip both caps together over the

adjusting screws in the position shown.
Use the installing tool to carefully

push the caps (1) one after another on to the adjusting screws (2).
Carburetors
915RA241 VA
57
915RA242 VA
Carefully screw the high speed

screw (2) and low speed screw (3) with washers (4) and springs (5) down onto their seats.
First push the white cap on to

the low speed screw so that the slot (1) is vertical and stop (2) points to the bottom right.
C3A-S39A
Pull the cap off the adjusting

screw. Note: Limiter caps are damaged during removal. They must not be used again. - If necessary, take out the adjusting screws with springs and washers and remove the retainer.
1 2
915RA243 VA
L
915RA245 VA
Basic setting
Push the red cap on to the high

speed screw so that the slot (1) is vertical and the stop (2) points to the bottom right (rich stop). - Push the caps on to the adjusting screws until they snap into position.

screws (H) and (L) firmly against their seats, open them one full turn.
4
915RA244 VA
3 4
Installation
Fitting limiter caps Note: Use new caps.
Fit the retainer (1).
58
915RA246 VA
Carburetors
915RA247 VA
7.20 7.20.1
Standard Setting on Tillotson Carburetors Fixed Jet Carburetors
HS-275A, HS-279B These carburetors have a fixed jet in place of a high speed adjusting screw (H screw). Maximum engine speed is preset and no longer adjustable. It is only possible to correct idling speed within certain limits. These carburetors guarantee an optimum fuel-air mixture in all operating conditions. Standard setting To readjust the carburetor, start with the standard setting.
L
915RA250 VA
The two stops limit the range of

adjustment.
915RA248 VA
LA

speed screw (L) clockwise until it is against its seat. Then back it off one full turn counterclockwise. - Check air filter and clean if necessary. - Inspect spark arresting screen and clean or replace as necessary.
915RA249 VA
270
- Start the engine and allow it to warm up. Adjusting idle speed Note: Use a tachometer.

only within a range of 270 degrees. - This enables the mixture to be made leaner, if necessary, for operation at high altitudes and prevents it being enriched beyond the emission limits specified by EPA. Adjusting idle speed Note: Use a tachometer. - Use idle speed screw (LA) to set engine speed to 2800 rpm.
Use idle speed screw (LA) to set

engine speed to 2500 rpm.
Carburetors
59
7.20.2
Carburetors with Limiter Caps
HL-366A, HS-280A, HS-281A, HT-12A
Carefully screw low speed screw

(1) and high speed screw (2) with springs (3) down onto their seats. Preparations - Check air filter and clean if necessary. - Inspect spark arresting screen and clean or replace as necessary. - Check chain tension and adjust if necessary.
915RA251 VA
Fit cap for high speed screw so

that it is against rich stop and cap for low speed screw so that its is against lean stop. - Push the caps on to the adjusting screws until they are flush with the molding.
HT-12A
Pull cap off the adjusting screw.

Note: Limiter caps are damaged during removal. They must not be used again. Basic setting - If necessary, take out the adjusting screws with springs.
915RA253 VA

screws (H) and (L) firmly against their seats, open the high speed screw (H) one full turn and the low speed screw (L) seven eights of a turn. 60
The two lugs on the molding limit

the range of adjustment.
Carburetors
915RA255 VA
915RA254 VA
Use idle speed screw (LA) to set

engine speed to 2500 rpm. Checking running behavior
180
915RA256 VA
- Open the throttle several times to check that engine accelerates smoothly. - Engine must run uniformly at idle speed.
1 3
915RA259 VA

only within a range of 180 degrees. - This enables the mixture to be made leaner, if necessary, for operation at high altitudes and prevents it being enriched beyond the emission limits specified by EPA.
Place module (1) in position. Carefully screw high speed

screw (2) and low speed screw (3) with springs (4) into module as far as stop.
915RA258 VA
HL-366A
Basic setting
Use a scriber to ease the caps

and rings out of the module. Adjusting idle speed Note: Use a tachometer. Note: Limiter caps and rings are damaged during removal. They must not be used again. - If necessary, take out the adjusting screws with springs. - Remove the module.
Starting with the high speed

screw (H) and low speed screw (L) firmly against their seats, open them one and a half turns. H = L = 1.5.
Turn low speed screw (L) one

quarter turn counterclockwise.
Carburetors
915RA257 VA
61
915RA260 VA
Important: The positions of the rings and adjusting screws must not be altered while aligning and fitting the caps. - Use carburetor screwdriver to push caps into the rings until they snap into position.
915RA261 VA
Adjusting idle speed Note: Use a tachometer. - Use idle speed screw (LA) to set engine speed to 2500 rpm.
Fitting rings and limiter caps Note: Use new rings and caps.
Fit the blue ring (1) over the low

speed screw (L) so that the markings line up. - Press the ring home until it is flush with the module.
Fit the red ring (2) over the high

speed screw (H) so that the markings line up. - Press the ring home until it is flush with the module.
180
915RA264 VA 915RA263 VA
90
Corrections are now possible on

the low speed screw within a range of 180 degrees and on the high speed screw within a range of 90 degrees. - This enables the mixture to be made leaner, if necessary, for operation at high altitudes and prevents it being enriched beyond the emission limits specified by EPA.
HS-280A, HS-281A - Turn caps counterclockwise as far as stop.
Screw puller (1) 5910 890 4500

into cap counterclockwise until it comes off the the head of the adjusting screw (left-hand thread). Note: Limiter caps are damaged during removal. They must not be used again. - If necessary, take out the low speed and high speed screws.
915RA262 VA
- Remove the module.
Align and fit caps so that the

caps flattened lug projects exactly into the slot in the adjusting screw.
62
Carburetors
Insert caps in the bores so that

the lug on the high speed screw points to the left and the lug on the low speed screw points downwards. - Push the caps on to the adjusting screws until they are flush with the module.
Place module (1) in position. Carefully screw high speed

screw (2) and low speed screw (3) with springs (4) into module as far as stop.
915RA265 VA
180
H 1/2 L 1/4
915RA266 VA
180
Basic setting

only within a range of 180 degrees. - This enables the mixture to be made leaner, if necessary, for operation at high altitudes and prevents it being enriched beyond the emission limits specified by EPA. Adjusting idle speed Note: Use a tachometer. Use idle speed screw (LA) to set engine speed to 1800 rpm.
915RA267 VA
Starting with the high speed

screw (H) and low speed screw (L) firmly against their seats, open them one turn.
Carburetors
915RA268 VA
63
7.21
Flow Chart
HD-13A, HD-16, HD-17, HD-18A, HD-21A, HD-22, WY-69, WT-329, WT-330, WT-367, WT-393, WT-489, WT-492, WJ-69, C1Q-SK7, C3A-S39A
Make preparations
Carry out basic setting
Adjust engine idle speed
Carry out full-load setting
no Running behavior ok?
yes
Secure caps
Remove both caps
no Running behavior ok?
yes
Carburetor adjustment completed
64
Carburetors
8. 8.1 No. 1 2 3 4 5
Special Servicing Tools and Aids Special Servicing Tools Part Name Carburetor and crankcase tester - Fuel line - Nipple Puller Screwdriver or Part No. 1106 850 2905 1110 141 8600 0000 855 9200 5910 890 4500 5910 890 2305 000 890 2300 Removing caps 1) Installing carb adjusting screws, adjusting carburetor Application Testing carburetor for leaks
8.2 No. 1 2
Servicing Aids Part Name White spirit Medium-strength adhesive (Loctite 242) 0786 111 1101 Part No. Application Cleaning all components Control valve, sealing plug, sealing plate, screw for throttle and choke shutters
1)
only carbs with limiter caps
Carburetors
65

Carburetor Repair Manual

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5. 5.1 5.2 5.2.1 5.2.2 5.2.3

5.2.5 5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.4

7.19.2 7.20 7.20.1 7.20.2

7.21 8. 8.1 8.2

Special Servicing Tools 65 Servicing Aids 65

1999 Andreas Stihl AG & Co., Waiblingen

full-load semi-fixed jet

choke shutter in carb

H, L with limiter caps

manual fuel pump x x x x x x x

full-load fixed jet

fixed idle jet

full-load semi-fixed jet

choke shutter in carb

H, L with limiter caps

manual fuel pump

full-load fixed jet

fixed idle jet

full-load semi-fixed jet

choke shutter in carb

H, L with limiter caps

manual fuel pump x x x x x x x x x x

full-load fixed jet

fixed idle jet

full-load semi-fixed jet

choke shutter in carb

H, L with limiter caps

manual fuel pump x x x x x x x x x x x x x x x x x

full-load fixed jet

fixed idle jet

Carburetors TS 510 TS 510 1) TS 510, 760 TS 760 TS 760 1)

CARB, EPA Accelerator pump

Idle system Part load Full load Setting Equipment

Operating Conditions Full Load

Idle jets - bypass bores

A lever mechanism connects the choke shutter to the throttle shutter.

The heating element (1) is positioned on the carburetor mounting studs.

Dirty Air Filter/ Compensator

Condition Carburetor floods; engine stalls

Condition Engine will not idle, idle speed too high

Engine stalls at idle speed

Set idle speed screw correctly Clean or renew valve jet

Engine speed drops quickly under load - low power

Flush dry carburetors with fuel

Push fuel line (2) 1110 141 8600

Connect testers pressure hose

Close vent screw (4) on the

Take out the screws. Remove the end cover.

Take out the screws.

Remove the gasket (1) and

Place the gasket (1) on the end

Remove metering diaphragm

Wet the pump diaphragm (3)

Carefully separate the

Carefully separate the

Fit pump diaphragm so that

- Remove metering diaphragm see 7.4.

Take out the screw.