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.............................................................
6s 1 6- 2
.6- 3 .6_ 4 .6- 4 .6_ 6 6- 8 - 8 .6_ 9 - 9 .6_fO .6_11 .6_11 .6-Q .6-Q .6_13 .6_13 .6_14 .6_15 .6_17 .6_17 .6_18 ..6_18 .6_19
.................................................................
................................................................ .............................................................. CONSTRUCT/ON ................................
CARBURETOR
SPEC/F/CA T/ONS ..................................................... I.D. NO. LOCA T/ON ................................................... DIAPHRAGM SLOW AND PISTON OPERATION .....................6
SYSTEM
..................................................... SYSTEM...........................6
TRANSIENT MAIN
ENRICHMENT
SYSTEM
STARTER FLOAT
SYSTEM
SYSTEM
.........
SYSTEM
.......................
O/L PRESSURE.
.............................
LUBRICATION
SYSTEM
LUBRICATION
SYSTEM
FUEL SYSTEM
A vacuum operated fuel pump is used to supply fuel from the fuel tank to the carburetor. lower than the carburetor fuel bowl. In addition, conditions The pump is necessary as the fuel cock is mounted across rough terrain. the pump assures
No. 2 carburetor
Fuel
Fuel pump
SYSTEM 6-2
FUEL COCK
A valve is provided With the valve ON at the top of the fuel cock (normal), lever and can switch over to OFF , ON and RES . the main passage opens. With the valve OFF , both holes close.
ON
position
RES
position
ON
WARNING: Gasoline is very explosive. Gaskets leakage. must Extreme care must be taken. with new ones to prevent fuel be replaced
LUBRICATION
SYSTEM
FUEL PUMP
Vacuum vacuum pressure pulsations
is
from
the carburetor
intake
When to the
fuel is drawn from the tank into the diaphragm chamber. As positive s back, pushing the fuel through
is applied,
carburetor. A series of check valves is used in the fuel flow route to allow the fuel to move in only one direction, through the pump body.
Fuel from
fuel
cock
Negat :ive
Fuel to carburetor
Positive
FUEL
AND
LUBRICATION
SYSTEM
6-4
CARBURETOR
CARBURETOR CONSTRUCTION
No. 2 (FRO INT) CARBURETOR
cable
@ @ 8 spring @
Main jet Main Pilot jet holder jet plunger screw valve hose top cap valve spring
@ @ @ @
stopper
plate
Needle
valve
0 @
valve jet
LUBRICATION
SYSTEM
No.
1 (REAR)
CARBURETOR
@ Fuel hose @ Coasting @ @ @ 0 @ @ @ Drain Float Float Needle Filter Main jet valve stopper screw Needle valve @ Gasket pin valve screw
0 @ @ @ @ 0 $$
Pilot
jet screw valve stop screw valve valve plunger top cap shaft return spring
@I Throttle
screw
@$ Piston Needle
valve jet
@& Fartburetor
IS on valve spring
SPECIFICATIONS
CARBURETOR
ITEM Carburetor Bore SIX I.D. No. Idle r/min. Float height Main jet Main air jet Jet needle Needle jet Throttle Pilot jet By-pass Pilot outlet Valve seat Starter jet valve (M.J.) (M.A.J.) (J.N.1 (N.J.) (Th .V .) (P.J.) (8.P.) (P.0.) W.S.) (G.S.1 (P.S.)
I
CARBURETOR
SPECIFICATION E-02.04. 15,21,25,28,34 MIKUNI BDS36SS (No. 2) c t t in) 9.1 f 1 .O mm (0.36 f 0.04 in) #I20 t 5D49-3rd t c #40 0.8 mm x 3 PCS 1 .O mm t # 22.5 (PRE-SET) l-l/B turns back No.1 : (# 65). No.2: (I .2 mm) t 7 I Carburetor Bore size I.D. No.
SPECIFICATION ITEM type MIKUNI BS36SS (No. 1) 36 mm 45C20 1200 + 50 rlmin. E-33 MIKUNI BDS36SS (No. 2) t t t 9.1 + 1 .O mm (0.36 f 0.04 in) #/f?L?.i t
I
type
MIKUNI BS36SS (No. 1) 36 mm 45coo 1100f100r/min. 27.7fl.Omm I1 -09 20.04 # 132.5 1 .B mm 5FlOB-3rd
Idle rlmin. Float height Main jet Main air jet Jet needle Needle iet Throttle Pilot jet By-pass Pilot outlet Valve seat Starter jet valve (M.J.) (M.A.J.) (J.N.1 (N.J.) (Th.V.) (P.J.) (B.P.) (P.0.) (V.S.1 (G.S.) (P.S.) (P.A.J.)
5D47-1
st
P-4 #115 #47.5 0.8 mm x 2PCS 0.8 mm 1.5 mm # 25 (PRE-SET) l-3/8 turns back No.1 : (# 70). No.2: (2.0 mm) 0.5 - 1 .O mm (0.02 - 0.04 in) 0.5 - 1 .O mm (0.02 - 0.04 in)
P-q
#125 #Y 0.8 mm x 2PCS 0.8 mm 1.5 -# 11,111
P-7 _
# 110 #YU 0.8 mm x 3PCS 1 n--11,111 I.
t
cl= L<
(PRE-SE.1 r, I No. 1: (# 65). hln 7. , ,? mm) ,.. &. \L.U ~___( 0.5 - 1 .O mm (0.02 - 0.04 in) 0.5 - 1 .O mm (0.02 - 0.04 in)
1
(P.A.J.)
Throttle
cable play
cable play
t
I
CARBURETOR
SPECIFICATION ITEM E-03 Carburetor Bore size I.D. No. Idle r/min. Float height Main jet Main air iet Jet needle Needle jet Throttle Pilot iet By-pass Pilot outlet Valve seat Starter iet valve (M.J.) (M.A.J.) (J.N.) (N.J.1 (Th .V .) 1P.J.) (B.P.) (P.0.) (V.S.1 (G.S.) 1200 type MIKUNI BS36SS (No. 36 mm 45ClO + 50 rlmin. in) MIKUNI BDSSBSS (No. 2) t t c 9.1 * 1 .O mm (0.36 * 0.04 in) # ir_ i ? t 5D47-1 p st
CARBURETOR
1)
1.8 mm 5E72-1 st P-7 #I25 #Yi 0.8 mm x 2PCS 0.8 mm 1.5 mm #25
No. 2: (1.2 mm) Throttle cable play 0.5 - 1 .O mm (0.02 - 0.04 in) 0.5 - 1 .O mm (0.02 - 0.04 inl t t
SYSTEM
CARBURETOR
SPECIFICATION ITEM Zarburetor Bore size I.D. No. Idle rlmin. Float height Main iet Main air jet Jet needle Needle jet Throttle PIlot jet Bypass Pilot outlet Valve seat Starter jet Pilot screw valve fM.J.1 (M.A.J.) (J.N.) (N.J.) (Th.V.) (P.J.) (B.P.1 (P.0.) (V.S.1 (G.S.) (P.S.) type MIKUNI BS36SS (No. 36 mm 4x40 1100f100r/min. 27.7fl.Omm (I .09 kO.04 in) E-01,16
CARBURETOR
I
Carburetor t t t
SPECIFICATION ITEM
I
U-woe
I
I)
type
I)
9.1 + 1 .O mm (0.36 k 0.04 in) # 122.5 t 5D49-3rd t t #40 0.8 mm x 3PCS 1 .O mm t # 22.5 (PRESET) l-l /8 turns back Thrnttle Pilot jet Bypass I Pilot outlet Valve seat Starter jet valve
1 /
ni 135
1.8 mm 5Fl OS-3rd P-4 #I15 rry47.5 0.8 mm x 2PCS 0.8 mm 1.5 mm f 25 (PRESET) l-l /2 turns back
I I
fM.J.1 (M.A.J.) fJ.N.1 (N.J.) fTh.V.l fP.J.1 (B.P.) fP.0.) (V.S.) (G.S.) (P.S.) fP.A.J.1
k 122.5
t
5D49-3rd P-6
I
1 1 I
#I15
t
#40 0.8 mm x 3PCS I 1.0 mm t # 22.5 (PRESET) l-l/16 turns back) No. 1: (# 651, No. 2: (I .2 mm) t t I
j: 47.5
0.8 mm x 2PCS 0.8 mm 1.5 mm ti 25 (PRESET) 1 -l/8 turns back No. 1: (3-f 70). No. 2: (2.0 mm) 0.5 - 1 .O mm (0.02 - 0.04 in) 0.5 - 1 .O mm (0.02 - 0.04 in)
__::::_
CARBURETOR
ITEM 1 Carburetor Bore size I.D. No. 1 Idle rimin. tvpe +Sf=$$;N
cable play
CARBURETOR
SPECIFICATION ITEM E-17 MIKUNI BS36SS (No. I) 36 mm 45070 1100 * 100 r/min. MIKUNI BDSBBSS (No. 2) t t t 9.1 i- 1 .O mm (0.36 f 0.04 in) # 122.5 t 5D49-3rd P-6 I + 1 I
Carburetor Bore size I.D. No. Idle rlmin. Float height Main jet Main air jet Jet needle
type
11100~100r/min.
27.7 f 1 .O mm (I .09 * 0.04 in) (M.J.) (M.A.J.) (J.N.) (N.J.) fTh.V.) (P.J.) (B.P.) fP.0.) (VS.) (G.S.) (P.S.) (P.A.J.)
I Needle iet I Throttle Pilot jet By pass Pilot outlet Valve seat Starter iet valve
/ 1
I I
+ t
#40 0.8 mm x 3PCS 1.0 mm t #22.5
Needle jet Throttle Pilot iet By-pass Pilot outlet Valve seat Starter iet valve
1 j / /
/
# 47.5
0.8 mm x 2PCS 0.8 mm 1.5 mm #25 (PRESET) l-3/8 turns back No. 1: (# 70), No. 2: (2.0 mm) 0.5 - 1 .O mm (0.02 - 0.04 in) 0.5 - 1 .O mm (0.02 - 0.04 in)
I /
# 40
0.8 mm x 3PCS 1 .O mm t # 22.5 (PRESET) l-114 turns back No. 1: (# 65). No. 2: (I .2 mm) t t
I 1
j 1
1.5 mm #25
Pilot screw Pilot air jet Throttle cable play 0.5 - 1 .O mm (0.02 - 0.04 in) 0.5 - 1 .O mm (0.02 - 0.04 in) Throttle
t t
cable play
FUEL
AND
LUBRICATION
SYSTEM
6-8
@I. Negative
is admitted
the diaphragm
in the piston
pressure
overcomes
for improved
fuel atomization
Negative
pressure
SYSTEM
SLOW SYSTEM
This system from (#I pilot float and #2) supplies chamber 0. fuel during engine rich with operation jet 0 with throttle valve @ closed or slight air coming pilot 8. 0. passage to pilot The remainder opened. pilot screw 0. The fuel air jets A part by @ is metered by pilot where it mixes with in through
of the mixture
into the main bore out of by-pass ports out into the main bore through outlet
is then metered
mixture
ed on cylinder This
side is applied
the diaphragm
air passage, thus, the pressure flows ing air flow in the pilot circuit.
Pilot jet
@q
Fuel/Air s Fuel
mixture
FUEL AND
LUBRICATION
SYSTEM
6-10
MAIN SYSTEM
As throttle Consequently Meanwhile, 0, in which valve @ is opened, in float then engine speed rises, and this increases negative @ is metered through by main jet 0, main air jet between @to pressure in the venturi @. the piston the fuel fuel it mixes with into the venturi valve @ moves upward. chamber and the metered fuel enters needle jet 0, and is fuel the air admitted passes through @, in which form an emulsion. @ and jet needle by the engine. which the emulsified
needle jet
it meets main air stream being drawn the clearance position. through ultimately on throttle
proportioning
is accomplished
Throttle valve (Q
..&$:~~~~~$& ::::,
.:$$$:.:.:.. . . . . . . .,....:,:.:
:.:,B
..../....:.. ,...,
,:::;::I :.
::?::
,..,
Fing
jet
.-..
--e---_
w-w--
-_ __-
-_ o-
-_ 0
\
Main
int m
6-11
FUEL AND
LUBRICATION
SYSTEM
STARTER SYSTEM
Pulling Starter up the starter shaft jet @ 0, fuel is drawn into the starter circuit from the float chamber 0. meters this fuel, which then flows into starter rich in fuel content, reaches starter plunger through a passage pipe @ and mixes with the air coming from the float chamber @ . The mixture, @ The and mixes two extending proper mixture bore. again with the air coming of fuel starting with
from main bore. successive mixings mixture for air are such that when the @ into the main is produced
fuel/air
FLOAT SYSTEM
Floats @ and needle valve @ are associated with the same 0 move up and down, the 0, floats @ are up and 0. As the fuel mechanism, so that, as the floats
needle valve @ too moves likewise. When fuel level is up in float chamber needle valve this condition, @ remains pushed up against valve seat. Under @ go down and needle valve @ unseats itself needle valve @ admits and shuts off fuel altera practically constant fuel level inside the
cr) ( \ /-fj carwretor
eedle 0
valve
lump
SYSTEM 6-12
Remove
the
synchronizing CAUTION:
cable 0
to the carburetors.
and
lay the parts out in groups designated as No. original location during assembly.
1 carburetor, to the
No. 2 (FRONT) @ : Syncronizing cable @ : Syncronizing cable adjuster @$ : Throttle cable (No. 2 carb.) @ : Throttle cable adjuster (No. 2 carb.) 0 : Throttle cable (No. 1 carb.) @ : Throttle cable adjuster (No. 1 carb.) 8 ; TrottIe stop screw crew 0 : Fuel hose
NOTE: Do not turn the throttle CAUTION: Do not turn the screw 0 Once removing a throttle the two carburetors. of the No. 2 carburetor. cable or the synchronizing cable or a carburetor body, it is necessary to balance cable adjusters @I , @ and the synchronizing cable adjuster @I .
DISASSEMBLY
l
Disassemble
the carburetors
as shown
in the illustrations
6-13
FUEL
AND LUBRICATION
SYSTEM
Check following * Pilot jet * Main jet * Main air jet * Pilot air jet
items for any damage or clogging. * Diaphragm * Gasket * Throttle valve shaft oil seals * Pilot outlet and by-pass holes hole * Fuel hose * Coasting valve jet
* Starter
If the seat and needle are worn trouble will the gasoline chamber as shown compressed not flow
beyond
parts with
illustration,
seat. Clean
the fuel
Float height
No. 1
No. 2
REAR CARBURETOR
09900-20102
: Vernier
calipers
FRONT CARBURETOR
@ to this
FUEL AND
LUBRICATION
SYSTEM
6-14
and remount
of disassembly Align
and remounting. to the following @ of the needle jet with the pin @ and
the groove
replace it.
of diaphragm
to the carburetor
body
When holes.
installing
the
coasting
valve
to the
body,
align
the
valve
by-pass
BALANCING CARBURETORS
No. 2 (FRONT)
: Synchronizing cable : Synchronizing cable adjuster : Throttle cable (No. 2 carb.) : Throttle cable adjuster (No. 2 carb.) : Throttle cable (No. 1 carb.) : Throttle cable adjuster (No. 1 carb.) : Throttle stop screw : Screw : Fuel hose
No. 1 (REAR)
CAUTION: Once removing the synchronizing @ , 0 or carburetors, carburetors. IN CASE @: As the first step, calibrate follows: 09913-13121 09913-13140 : Carburetor : Adapter for warminspection @ balancer the carburetor balancer gauge, as OF CHANGING THE SYNCHRONIZING CABLE cable @ or throttle cables it is necessary to balance the two
Start up the engine and run it in idling condition ing up. Stop the warm-up screw @ with gasket. Connect engine. Remove the vacuum for No. 2 carburetor
one of the four rubber hoses of the balancer gauge stop screw @I.
to this adapter, and start up the engine, and keep it running at idle speed by turning throttle NOTE: The idle speed is different and 7.) among the countries. (See pages 6-6
FUEL
Turn
@ of the gauge so that the vacuum hose will bring the steel ball line 0. the steel ball Turn stays steady the adapter
act@ in
ing on the tube of that the tube to the center After center nect making the next sure
that
at the
line, disconnect
and conhas
the other
been calibrated. Remove Connect the vacuum inspection with balancer screw @ for No. 1 carburegasket. gauge hose to their respec-
the adapter
each calibrated
Warm up the engine, Under two screw this condition, level at the center carburetors 0 and turn
and keep it running see if the two line, as they should, if not,
are in balance:
adjuster
CABLE balancer
@, 0: gauge at the
first
r/min,
remove the No. 1 carburetor. the throttle cables inner length the adjusters @I ,O after
Be careful not to twist the throttle Throttle carburetor 6-6 and 7.)
cables 0,
0.
cable adjuster @ can not be turned when the No. 1 is installed to the engine. among the countries. (See pages
SYSTEM
balancer by
at 1500 r/min. and keep it running grip. see if the two line, cable as they adjuster if not, steel balls stay equally to signify the two loosen the lock nut and @ to adjust the throttle level line. should, at 1500 r/min
are in balance:
the throttle
the throttle
make sure -
that each throttle cable have enough play. IN CASE OF CHANGING When changing synchronizing carburetor, forming THE CARBURETORS it is necessary to adjust IN CASE to remove the the THE cables. So once removing OF CHANGING
it becomes
above two
cable.
LUBRICATION SYSTEM
OIL PRESSURE
Check the oil level in the inspection pressure in the following Install Install figure. Warm up the engine as follows: Summer Winter After 10 min. at 2000 r/min. 20 min. at 2000 r/min. warming up operation, increase below: the engine speed to and read the oil pressure gauge. manner: bolt. shown in the 0. Remove the oil pressure inspection the oil pressure adapter the oil pressure window and check the oil
3000 r/min,
Above 350 kPa (3.5 kg/cm*, Below 650 kPa (6.5 kg/cm*, Oil temp. at 60C (140 F)
CAUTION: The recommended low-40 motor oil. : Oil pressure gauge : Oil pressure gauge (meter) : Oil pressure gauge adapter engine oil is, API classification SE or SF,
NOTE: Engine oil must be warmed up to 60 C 1140 F) when checking the oil pressure. If the oil pressure is lower or higher than the specifications, oil
several causes may be considered. * Low oil pressure is usually leakage from * High tion the result of clogged oil filter, of these items. caused by a engine oil which installais the oil passage way, is usually damaged oil seal, a defec-
tive oil pump or a combination oil pressure of the oil filter too heavy a weight,
OIL FILTER
Refer to page 2-8 for installation procedures.
6-19
FUEL AND
LUBRICATION
SYSTEM
LUBRICATION
SYSTEM
Epy
INTAKE
Ii
J:
ROCKER ARM
1 CAMSHAFT 1. JOURNAL ) 1
CAMSHAFT
R. JOURNAL
;;;I$ 1
CLUTCH
1_I
1. CRANK JOURNAL f
R. CRANK JOURNAL t
MAIN GALLERY
/ DRIVESHAFT
rOlL
PANZ
elf7
FUEL
AND
LUBRICATION
SYSTEM
6-20