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5. FUEL SYSTEM

5-0

MX’er SYSTEM

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FUEL SYSTEM

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SERVICE INFORMATION -------------------------------------------- 5- 2

TROUBLESHOOTING ------------------------------------------------- 5- 3

THROTTLE VALVE DISASSEMBLY/CARBURETOR REMOVAL- 5- 4

FLOAT/FLOAT VALVE/JETS ---------------------------------------- 5- 5

CARBURETOR INSTALLATION ------------------------------------ 5- 8

FUEL TANK------------------------------------------------------------- 5- 9

FUEL VALVE REMOVAL -------------------------------------------- 5- 9

AIR CLEANER ---------------------------------------------------------- 5-10

Summary of content (11 pages)

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5. FUEL SYSTEM MX’er SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS Gasoline is very dangerous. When working with gasoline, keep sparks and flames away from the working area. Gasoline is extremely flammable and is explosive under certain conditions. Be sure to work in a well-ventilated area. • Do not bend or twist control cables. Damaged control cables will not operate smoothly. • When disassembling fuel system parts, note the locations of O-rings. Replace them with new ones during reassembly.
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. FUEL SYSTEM THROTTLE VALVE DISASSEMBLY Remove the front cover. Remove the front fender. Remove the carburetor cap. Pull out the throttle valve. Disconnect the choke knob cable. Disconnect the throttle cable and remove the spring from the throttle valve. Pry off the needle retainer and remove the jet needle. Check the throttle valve and jet needle for wear or damage.
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5. FUEL SYSTEM MX’er SYSTEM Lock Nuts Loosen the air cleaner connecting tube band screw. Remove the two carburetor lock nuts. Remove the carburetor Screw FLOAT/FLOAT VALVE/JETS FLOAT/FLOAT VALVE DIS AS SEMBLY Remove the float chamber attaching three screws and remove the float chamber. Screws Remove the float pin, float and float valve. Float Float Pin FLOAT/FLOAT VALVE INSPECTION Inspect the float valve seat for wear or damage. Inspect the float for damage or fuel level inside the float chamber.
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5. FUEL SYSTEM MX’er SYSTEM Slow Jet JETS/AIR SCREW/THROTTLE STOP SCREW REMOVAL Remove the main jet, needle jet holder, and needle jet. Remove the slow jet. Remove the air screw and throttle stop screw. Air Screw CAUTIONS ! ＊ • Be careful not to damage the jets and Air Screw Main Jet Throttle Stop Screw O-ring Slow Jet jet holder when removing them. • Before removal, turn the throttle stop screw and air screw in and count the number of turns until they seat lightly and then make a note of this.
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5. FUEL SYSTEM MX’er SYSTEM SLOW/MAIN JET INSTALLATION Install the slow jet. Install the needle jet, needle jet holder and main jet. Install the throttle stop screw and air screw Slow Jet Main Jet ＊ • When installing the air screw, return it to the original position as noted during removal • After the carburetor is installed, be sure to perform the Exhaust Emission Test. Throttle Stop Screw Install the float valve, float and float pin.
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5. FUEL SYSTEM MX’er SYSTEM Lock Nut CARBURETOR INSTALLATION Install the carburetor onto the intake manifold and tighten the two lock nuts. Torque: 0.8_ 1.2kgf-m Install the air cleaner connecting tube and tighten the band screw. Band Screw Clip THROTTLE VALVE ASSEMBLY Install the jet needle into the throttle valve and secure with the needle retainer.
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5. FUEL SYSTEM MX’er SYSTEM Screw Tighten the choke cable. FUEL TANK FUEL TANK REMOVAL Choke Cable Side Warning • Keep sparks and flames away from the work area. • Wipe off any spilled gasoline. Remove the seat. Remove the center cover. Remove the right and left front fender. Switch the fuel valve “OFF”. Disconnect the fuel tube and remove two bolts on the end of the fuel tank. Remove the fuel tank. Bolts Fuel Tank Tube FUEL VALVE REMOVAL Remove the fuel valve and fuel cup.
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5. FUEL SYSTEM Remove the screw on the fuel valve control switch. Remove the two screws on the fuel valve body. MX’er SYSTEM Fuel Valve Body Washer Control Switch INSPECTION Inspect the fuel valve strainer for dirt and clog. Clean if necessary. Replace the O-rings with new ones if they are damaged or deteriorated. Rubber Gasket AIR CLEANER Control Shaft Retaining Ring Air Cleaner Case Cover REMOVAL Remove the seat. Remove the four screws on the air cleaner case cover and the cover.