Just imagine how much you can save by doing simple repairs yourself. Many people buy this manual just to have it around for when the inevitable happens. Sooner or later, maintenance will need to be performed. Be prepared for it when it happens by simply purchasing this service manual for later use! See below for a list of items that most of our manuals cover. First name. Last name. Your cart is empty. Add to cart. Share this product.
Recommended for advanced users. The kit does not come with instructions. Customer Reviews. We're Here to Help We have the best customer service and education in the industry. Serving You Since Since , we've shipped over 1 million orders to happy customers. Log in Register. Search titles only. Search Advanced search…. New posts. Search forums. Log in. Install the app.
For a better experience, please enable JavaScript in your browser before proceeding. You are using an out of date browser. It may not display this or other websites correctly. You should upgrade or use an alternative browser. Jackshaft Shift Kit Questions for anyone thats allready installed one. Thread starter sactownie Start date Aug 2, Joined Jun 3, Messages Hi people. Doing my 1st install and have some questions maybe someone knows the answers? What size chain do you run on the engine to jackshaft sprocket?
I'm trying to use from the engine kit, It looks like its going to rub the jackshaft plate. The engine sprocket wont accept bmx chain, my guess the sprocket to wide? View, sign, comment on, and share PDFs for free. Please select your operating system and language to download Acrobat Reader. A version of Reader is not available for this configuration. Optional offer:. To remove the assembly, you remove the screw that holds the shaft in place. Be careful not to loose the spring. It's not included with most kits.
The round gray component in the image above is a 'Welch' plug. If a carburetor is extremely gummed up, it may be necessary to clean out the idle ports. The only way to properly clean them is to break this plug out and clean the area behind it. You'll need a replacement so don't break the plug out if you don't have a replacement. If you think this area will be dirty, you can order a kit that includes the Welch plugs. The orange arrow in the next photo shows you the port that allows the fuel to flow from the metering chamber to the high-speed jet.
The red arrow points to the port that allows fuel to flow to the low-speed jet. The return spring for the metering lever can be difficult to work with, especially if you have big fingers. If you take a length of monofilament fishing line make a loop in it then insert it through the hole in the lever and then into the spring, the spring won't be so difficult to work with.
You can also insert the loop through the hole in the lever when disassembling the metering valve assembly to help the lever and spring together. Heavier line works a bit better because it doesn't pull out as easily. Line that's easier to see is easier to work with. This is 30lb test Red Lightnin' line by Zebco. Fuel Pump: The following image shows the fuel pump assembly.
THIS is what the carburetor looks like before removing the cover. The main component of the fuel pump is the diaphragm.
It contains the reed valves that act as check valves to force the fuel to flow in one direction. The fuel pump is actuated by pulses of air from the engine crankcase. The port 'W' is where the carburetor mates to the port in the head. It's ported to 'X'. When the fuel pump cover is in place, it mates to the 'X' that you see on the cover. Air pulses pass to 'Y' through the fuel pump cover.
That causes the diaphragm to pulse which actuates the fuel pump reed valves. The fuel path is shown in red and progresses in order. The points with the same letter on the cover and on the body of the carburetor are mated when the cover is in place. Note: The image above is a Flash graphic. You can right-click on it and select 'zoom in' from the dialog box. Drag the image with the left mouse button to navigate when zoomed in.
This image has Dacron fishing line through all of the passages in the body of the carburetor to show you which ones are connected. All of these passages as well as the fuel filter must be clean and free of varnish. If any trash gets under either of the fuel pump reed valves, they will not function properly and the engine will not run. High and Low Speed Jets: On some 2-cycle carburetors, you will have two adjustable jets. One is for high-speed operation and one is for low-speed idle operation.
These are typically marked. Below, you can see the markings on the body of the carburetor.
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