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  1. #11
    BlueFishCrisis's Avatar
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    After the carb body is cleaned and prepped, take the valve body assembly and flip it over. There is a small phillips screw and a retaining plate. Look closely and you will see a small clear plastic check valve. These need to be removed and discarded as new check valves are included in the kit.

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Name:	033 remove clear valve retainer.jpg 
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ID:	331845Click image for larger version. 

Name:	034 old clear valve.jpg 
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ID:	331846

    Finally, remove and discard the old o rings from the high and low speed adjusters. These too are included in the kit.

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Name:	035 remove o rings from needles.jpg 
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ID:	331847


  2. #12
    BlueFishCrisis's Avatar
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    Now that everything is clean and prepped, I next like to layout all my parts and screws to make sure I have everything needed for reassembly. This is the time I take inventory, and decide to replace any parts that are beyond recognition, badly corroded, or had to be destroyed to be removed. Most of the parts were in good condition, so I am re-using them here.

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Name:	036 lay out parts for reassemble.jpg 
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ID:	331848

    At this time I also like to take the "old" rubber parts and stick them is a small zip lock bag with some 2 stroke oil to prep them for re-assembly.

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Name:	037 rubber parts in bag.jpg 
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ID:	331849Click image for larger version. 

Name:	038 rubber parts in 2 stroke oil.jpg 
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ID:	331850

  3. #13
    BlueFishCrisis's Avatar
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    Let's start re-assembly with the Valve body assembly. Locate the new clear check valves in your kit. Be careful when opening, as they are very light and easily will disappear into your surroundings.....

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Name:	039 new clear valves in bag.jpg 
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ID:	331852Click image for larger version. 

Name:	040 new clear valve.jpg 
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ID:	331853

    Install the new check valve with the retaining plate and screw. Note the check valve has two holes. One for the screw, and one for the locator pin on the plate. This keeps the valve in the proper position once installed.

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Name:	041 Install new valve and retaining.jpg 
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ID:	331854Click image for larger version. 

Name:	042 install retaining screw.jpg 
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ID:	331855

  4. #14
    BlueFishCrisis's Avatar
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    Pay close attention, as this valve CAN be installed backwards.

    Correctly installed:

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Name:	043 correctly installed valve.jpg 
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ID:	331856

    Incorrectly installed:

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Name:	044 incorrectly installed valve.jpg 
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ID:	331857

    All three complete......

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Name:	045 all three complete.jpg 
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ID:	331858

  5. #15
    BlueFishCrisis's Avatar
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    Next let's install the jets and the valve body gasket.

    High speed jet:

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Name:	047 install high speed jet.jpg 
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ID:	331859

    Low speed jet:

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Name:	048 install low speed jet.jpg 
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ID:	331860

    Valve body gasket:

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Name:	049 install rubber gasket.jpg 
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ID:	331861

    Note the gasket is wet with oil from the zip lock bag.....

  6. #16
    BlueFishCrisis's Avatar
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    Install the valve body assemblies with two phillips screws.

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Name:	050 install jet cover.jpg 
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ID:	331862

    At this point, I open the balance of the parts from the kit and install the needle and seat. In this kit, the needles are packaged with the seats with a clear dome keeping them together.

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Name:	051 balance of new parts.jpg 
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ID:	331863

    Needle and seat:

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Name:	052 needle in seat.jpg 
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ID:	331864Click image for larger version. 

Name:	053 needle in seat.jpg 
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ID:	331865

    I like to put a bit of 2 stroke oil on the o ring on the seat to help it into the carb body.

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Name:	054 oil seat.jpg 
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ID:	331866

  7. #17
    BlueFishCrisis's Avatar
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    Push the seat into place, then install the plate retainer and screw.

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Name:	055 install seat.jpg 
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ID:	331867Click image for larger version. 

Name:	056 install retainer and screw.jpg 
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ID:	331868Click image for larger version. 

Name:	057 seat installed.jpg 
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ID:	331869

    Next install the new spring. Re-use the springs from a 780 sized motor.

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Name:	058 new spring.jpg 
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ID:	331871Click image for larger version. 

Name:	059 new spring installed.jpg 
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ID:	331872

  8. #18
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    Before installing the new needle, I like to spray a bit of multipurpose lubricant like WD40 into the seat.

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Name:	060 oil seat.jpg 
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ID:	331873

    Install the lever, pin, and needle assembly.

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Name:	061 install lever pin and needle.jpg 
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ID:	331874

    When you set this assembly in place, make sure the spring is properly seated on the raised "dimple" in the lever arm.

    Not properly seated:

    Click image for larger version. 

Name:	062 spring not seated.jpg 
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ID:	331875

    Properly seated:

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Name:	053 spring seated.jpg 
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ID:	331876

  9. #19
    BlueFishCrisis's Avatar
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    Next install the screw which retains the lever pin. I use my left index finger to hold the assembly in place while installing the screw. Of course, I couldn't take a pic at the same time!! You get the idea.....

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Name:	054 hold lever in place.jpg 
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ID:	331877Click image for larger version. 

Name:	055 Install pin screw.jpg 
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ID:	331878Click image for larger version. 

Name:	056 ready for diphragm.jpg 
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ID:	331879

    Next I like to apply a bit of oil to the groove where the diaphragm rests.

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Name:	057 oil diaphragm groove.jpg 
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ID:	331880

  10. #20
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    Install the diaphragm and cover.

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Name:	058 new diaphragm.jpg 
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ID:	331881Click image for larger version. 

Name:	059 install new diaphragm.jpg 
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ID:	331882Click image for larger version. 

Name:	060 install diaphragm cover.jpg 
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ID:	331883

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