| Walbro DIAPHRAGM CARBURETORS | Eq = 5 < = ff 9 > rs ul 7)INTRODUCTION... AIR AND FUEL. ALTERNATIVE FUELS.... TWO-CYCLE ENGINES......... THE FUEL METERING SYSTEM. BUTTERFLY VALVE CARBURETORS... VENTURI OPERATION... TROUBLESHOOTING... Determining Cause. Pressure Testing. Hard Starting Hot. No Idle. Poor Idle. Poor Acceleration. Poor High Speed. . Carburetor Disassembly. CARBURETOR REBUILD. Mixture Screws. Fuel Pump. i Welch Plug Removal Circuit Plate Removal. MAIN NOZZLE CHECK VALVE. REASSEMBLY.. PRESSURE TESTING.. ADJUSTMENTS... cores easee BARREL VALVE CARBURETOPS...... BARREL VALVE CARBURETOR ADJUSTMENTS.. AIR PURGE SYSTEMSG.... PRIMER SYSTEMS.}.. ACCELERATOR SYSTEMG.............000:cssssssseesssssneeeeesnsieemennessennnneene 28, 29 GOVERNOR... TOOLS cesses cence ee cette eee ene : 7 31 Walbro Corporation 1A civerse asthe Walbro diaphragm carburetor Tine has become, producing a manual to detail the repair of each specific Walbro carburetor would be a monumental task, and the manual would be ‘obsolete as soon as it was printed. Instead, what ‘we hope to do here is to show you the individual ‘components that ate found in various combina- tions within our carburetors and show you how to troubleshoot and service them. ‘We hope this manual becomes a useful and profitable tool in your shop. As we develop new carburetor technologies, we will try 1o keep you up t0 date on further service techniques. If you have any suggestions or additions to the next priming, please send us a note. Sincerely, INTRODUCTION Ao fs Lis J. Salas Field Service Supervisor Aftermarket Divi Walbro Engine Management Cocp. 2 Walbro CorporationThe Aictekon into an cogincis what actually creates the power within the engine, Of course, the airs useless ‘without fuel Buel boming causes the aie to heat anc ‘expand creating the power of dieengine. The anount of power created is a function of thc amount of ai taken inte the cylinder. Ia small arount of sit is avr into the eylinder, the air donsity is low and a ‘small amountof poweris produced. Since the engine is under a ceciain amoutt of internal snd external ‘dag, the power prodduced slightly overcomesthe dag ‘and the engine rune slowly, As more aie is admitted into the eylinder the air density becomes higher and snore power is produced. The engine runs faster, oF am carry a bigger load Ton enn hes pu Se erent Crenmn ryoncore pies cesar pean ae eerinere eet t aii aoe Tying sows rca pete ie concent vate voneuitineee Renan seece etek ots witnren ees Biscay tour arene ny ae Siler caee meete serous a dss aay mere eres ers The Fuels For any fuel te burn most efficiently it must be combined with a specific amount ar, This specific aiffucl rai is called the stoichiometric. Ompress ‘your friends with that ode!) For gasoline, the best ‘atio is 14.6 Ibs. of air for cach pound of gasoline. At this rao all he available iris combined with alt the available gasoline to get the mest power and Ieost emissions outoftheengine, Unfortunately. anengine will pot survive running atthis 14.64 ratio; it would quickly overteae, Foranengine tosurvive, Anusteun an aitsfcl ratio that is abit riches. ‘Acch waiature combais unre Fue] than the “lea Most engi taratio of 10.5:1 to 12:1, provid ag them of oxcess fuel. The ent uel is used 10 cool the cylinder components as the engine ‘uns, Since some fuel is being wasted a rich setting, ‘emissions aze higher and power is slightly less: we want the engine to run just rich enouch to keep coo ‘This isthe mixture at which the carburctor is gener: ally sot. Opposite ofa rich mixture sa lean mixture - tea much air and eat enough fuel, Again, running Jeam ‘vill overheat the engine, Hot engines lose thvir oper ating telorances and seive. Hot engines areatso prone todeconation,anexplosive uneven buming af the uel within thzeylinger, Detonation puts extemeloadson ‘cing parts causing in 10 Call Bea thd Walbro Corporation 3co = a =) ng rt 2 = 7 Zz ia ui = 4 4 Walkro Corporation Alternative Fuels The other two fuels that are sometimes used (generally as high performance alternatives to guso- line) are he alcohols: methanol and ethanol. Both of these fuels require a much richer misture than geso- Tine. Mehanol needs an air-fuel rai of 64:1, ot about 2.25 times more fucl-to-airthan gasoline, Etha- nolrequices an air-fut raioof 9:1, orabout 6 times the fuel-p-air of gasoline. So ifittakes somuch niore alcohol to get the same ower asgasoline, why is it used as « bigh perfom- ace fuel? First, aloohols have 2 much higher octane than gsolinc,and an engine can be built 0 run at higher Comprestion ratios without detonation, so theengine ‘ean prodice more power. NOTE: This offers no benefit fer a standard gasoline engine, ‘Sccond,aicohols havea higher laten: heat ofevapo- ration. Insther words, it takes more heat to evaporate alcohol than gasoline. Notice how cool a runing carburetor gets; it takes heat to vaporize any liquid. ‘Alcohol tkes tke heat from the iniake ar the-cooled alr is doneer) and the dense air packs the cylinder ‘Ughter, resulting in more power. An engine running, ‘on 100% methanol will produce about 15% more ower then when running en gasoline. Of course, i ‘willalso burn over twice as much fuel get thatexira 15%, Third, aicohol fueled engines run cooler tian gaso- fineeagines. Bit keep in mind that iPan engine is ran ‘onalcoho. while thocarburctor i st for gasoline, the engine will be ramning leaner and houter. Walbrocarburetors can tolerate the legal limits of alcchols present in todays fuels: 10% etranol, 59% methanol, and 11% of the octane enhancer MTBE (Methyl Tertiary Butyl Ethe:), Careless blending can sometimes esullin percentages exceeding theselevels ‘on a local basis. You may have noticed that the ‘material a the Gp of the inlet needles is now a red colered vion, and that several fusl pumpdiaphragins. are aow made from a brown colored woven fiber- glass. These new componenis were developed to crease tre alcohol resistance of ourcarburetors. No carburetor will cusrenily handle 100% alcohol fuels for an extended period, If you wish to use alechol in ‘high per‘ormanc: application, we recommend you contact @ local race shop for advice on carburetor modifications, ‘You can see from this sheet discussion on air and fuel thatth: carburetor has animportant job. Net only does it maintain a constant proper aiz:fuel ratio, it ust do sc Eoughout all ihe various speeds, loads, ‘nd running conditions that the engine faces. We are "ow ready to continue on and lear how it accom- plishes wis,Air Induction on the Two-Cycle Engine “There ae thee basic forms of induetion onthe 2- cece engine: rosary valve, reed valve and piston pore, We'll diseuss red valve and piston port here since these are the rcst common in the small engine industry. Rotary valvos aze genaelly found only on movoreycles and suewinables. ‘The low pressure neded 10 draw air trough te ‘carburioriscreaed by the motion ofthe piston, but in the 2-cycle engine the ait is drawn in below th Piston into the crankease, Thisis known as erankeaso ‘pomping. Crankcase pumping is erated by the pis- nid tonsa therings andi maintained by Urecranksialt rickesp genden'¢ sealbandgasketsyandtheylinder gasket Ontheread Sprgibeaed ane sar valve style engine a thin etal or plastic reed i sed ‘ocasure atthe ar only flows in through te carb i Felor, and doesn’t tow back oat on the downiard suoke of te piston, The piston ported erg allows thepisionskir toprovidcthisenetionoftbeane-way vale ‘As the piston moves dour, thor abtovothcayh ts | pure cearburetr Ane stare pushed trough tne Atanatr ports tothe comtuston {hana ores the lstcn shrtsaa One tg atvanage of te Leyeleenive, set featur, ‘oe must ‘so have a carburetor which can FUEL PUMP. |__NETERING DIAPHRAGM opera inary poston Teor opcat ity Peston testes mal depeningongauiy | —*EARERG) i. flowtuslgwen}acetiotoronbecd denen | REPLACESGRAVITYRLOW REPLACES FLOAT cal devies. The dopa eaburtr places he floatvitha mecring aphragmad ss ul pan o Inplac of praviy fet | The Fuel Pump System ‘Tne power locporate the fas] pump comes from the ‘crankcase impulse. The pressure and vacuum pulses travel through cither a drilled passage or an impulse Tive. The pump is made up ofthe diapheagm bubble aa series of chock valves. The fuel pump provides pressure which the restof the carburcior depends on. 4s the piston moves up into the eylinde iterates & low pressure arca in the crankcase, This vacuum pulse vayels dough the impulse passage and draws uponthe pump diaphragm creating a vacuum within the ful chamber. Atmasphetic air pressure is al- owed into the Fuel tank and pushes the fucl through ‘the Fue fill he uel linc, and opens the inlet check valve to fil de vacuum, The vacuum closes the foe! pumps discharge chock valve, FUEL PUMP INTAKE __ Walbro Corporation §Meuse Fue rutpunp piscance 6 Walbro Corporation As dhe pston moves down into the crankcase it pressurizestheair. Thepressurizedair raveischrough the impulse passage into the carburetor fue! purnp; ik then pressesdown on the diaphragm pressurizing the fuel, The pressurized fuel then closes Whe inet valve ‘and opons the discharge valve in tho fuel pump. From the purnp, the fuel tuvets to the fuel inlet sercen, The seresn has an ionportant job as the final proicstion azainst dit the inlet needle and the scat. “The inlet sce is sized in conjunction with the foe flier selected by the engine manufacturer. ‘The inlet acedle snd seat coir fuel flow throagh the carbureoe. It is essential tbat they be in good ‘condition forthe carburetor to fametion properly. The actual scalirgarcanceds tobe quite small iosealback the pressurefiom the fuel pump. Because ofthe smal seat area, th inlet weedic and seat are susceptible 10 leaking caused by dicand Gebcis, Walbro carburetors ‘will ether bave a machinee-in aluminam seat or a prescod-in frase seat. "The pressed-in scat used cy foz esse of ranutaciuring; itstould nothepeessedout for serve. The Fuel Metering System ‘There ate four comporents to the Fel meting, system: 1) te Metering Diaphragm 2) tbe Metering Lever; 3) the Motcing Springjand 4) the TnlotNecdle “The moecrg apbragm ina very sensitive device, I ‘st respond instanly wo sight changes in de fuck acuumwitunthe meteangchumber: she dapheagen isirad of ante rsbbercompondover woven silk, with the coavolution molded in to allow for grater ovement. stiffener plate asic bullon are tached atthe cent, Because he diaphragm mus respond 12 cat intake stoke of dhe engin, it tmast be of the proper weight and resiliency. ifs Ww ST oF too heavy, wil no spond fast cxsgh and The engine will tarve ‘or fuel at high speeds The meting lever ransfers the pressure of tke spring t De ink} needle, holding the neve closed andl preveiving fuel from flowing from the pump. ‘When ihe egincis sunning. he netoring fever docs fot ifthe nova off the sea; since the nee tip is tues pressize fom the uel pump, itis ofT te seat ass00n. asthe motoring dpa travels far ene ugh down to orertide the spring force. Motring lever ight is very important ineantrolfing when and how farthe inlet nocd ops. If thc lever is set 100 igh, dcengineniay sui ifitis taotow doe engine will run leanThe metering spring does more than simply close the inlet ncedle. Italso helps determine the accelera- tion and deceleration characteristics of the engine. ‘The spring must allow the valve w open al just the right moment on acceleration or the engine will stumble, and it must close atthe right time when the UuxoUle is closed or the engine will flood. Therefore, itis important o maintain the proper metering spring in thecarburetor. We’ lliookal the metering systemas it functions withthe entire cerburcter. Start Up ‘Theengine at start up has numberof requirements that differ from usual operation, The engine is often times cold; a cold engine isnot as efficiem: st vapor- ining fuel because heat is required to vaporize lau. ‘Cranking speedsaremuch lower transuming speeds, soieflow through thecarburetoris notstzong enovgh to make fuel flow into the airstream. Fonunately these two problems can be overcome by creating a ich fuel/ic mixture Thisisdone with eihera primer = which injecis extra gasoline inta the carburetor throat ora choke which greatly inersaaca the vac tuum in the carb throat allowing n unusoslly high ‘amount of gasoline o enter the inuake ai. With the choke closed, the intake vacuum of the engine is Tmainiained within the carburetor throat. This high vacuum causes all the earburctor's fuel nozzles 19 ‘diver the fuel into the intake ir stream Idle ‘Once theengine stans, the chokeisopened and the ccugine is idling. At idle, the throttle plate is nearly loved, There is low pressure on theengine side of tie aie and high pressure (atmospheric pressure)on the ‘her side, The high prossure air lows into the re- raining transition holesand mixes with the fuel inthe idle pocket, Fuel fs drawn out of the idle pocket into the low procsure-sa-the-engine side of the throttle plate. AS the fuel is drawn out of the idle pocket it ‘creates a Jow pressure throughout the metering sys- tem. Atmospheric air enters through the vent and presses ont the meering diaphragm. The diaphragm presses on tho metering level, releasing dhe spring pressure off the inlet needle allowing enough (vel 10 ‘cone in io replace the fuel drawa out on that suoke. 00-608 Spring KE Fu PULSE] INTAKE ARI ENGINE, vacua Fue pute} nCTAKE 2 ENGIN vaCUUN = wo 5 m BY Bu wr < al < i 9 > Es i] = a fu a fo) ES wo Walbro Corporation 7IMPULSES TAKE AI ENGINE, INTAKE AIR) ENGINE, vacuun a F i} F TT} iy ° rs = 2 Ww E LOW PRESSURE p—— Hien veocnry 8 Walbro Corporation — hick PRESSURE Low vetociry | Part Trrottle ‘Atmoderate throule settings, the trotte plae has ‘opened farther wallow increased air into tiecombus- tion chamber. In order to maintain the propes air/fuel ‘mixture, additional fuel mast be mixed in, This fuel comes fiom the idle progression holes. On most diaphragn carburetors ao air comes out ofthe pro- gression holes at part throtle, There are some diae phragm carburetors that do have an air blezd for the idle cirevt. These usually appear as a small hole lacing hom the outside ofthe carb body into the idle Docket. The air bleed helps to atomize the fucl and hheips prevent intake manifold pudding. Puddling is the build:p of gasoline in a pool, which then gets sucked irto the engine and causes the engine 10 go rich, AL fact tnrotde the main nozzle begins to com tribute fas, Wide-Open Throttle Operation As thethrotde plac is opened farther, it has les effect on te location ofthe high and low pressine atcas wivin die carburetor throat. At wide-open thao, air quickly ruses tough te carburetor io Till the cylinder. Since air refills the cytincer soan alter the intake vacuum is created, Uhre is not much Jow presswe air (vacuum) withinthe carburetor iat low presure area must be creatod within the thront to draw fel into the ar stream. This low pressure is created with a venuri, NOTE: Depending on the carburetor design, the idle cizeuit may or may not deliver Fal at wide-open thoi Operation of a Venturi ‘Weatteaptto force dhesameamount of ar throug the resucion of Ue venturias satay” lowing Ltweugh te larger front and back of the carbureior tot. To get the sane amount of air through a smaller le, the air must sped up. As it speods up, its pressure drops. This low pressure created at Ute ‘Venturi dew fuel out ofthe main nozzle,The high speed nozzie is positioned so the venturi vacuum draws fuel into the carburetor throat. Main Nozzle Check Valve ‘The main nozele is under aunospherie pressure when the engine is at igle and low shroie, and it’s, ‘undera vacuum when the engine isatmediumand.ull ‘throttle. To prevent ihe hish pressure rat idle from bleeding back into the fuel passages (which would aisrupt the idle mizture),wwe musi placcackeck valve in the high speed fuel passoge (usually right atthe ‘main nozzle). The check valve allowsthe fueltoleave the main nozzle, but does net allow ais to come in ‘We have Looked.at what happens within the carb retor os it runs from startup 10 wide-open throitle, how we'll look at woubleshooting carburetor prob- loms and eompancns Troubleshooting Carburetor Problems Since the carburetor is so dependent on the opera: tion of the engine to do its job, your first step in ‘woubleshooting is to determine if you have a cerbu ‘tor or an engine-caused problom. We will assume ‘you have already performed the needed esis on the ignition and compression systemis,as problems within these systems can be mistaken for carturetor prob. fems. Its helpful to be ableto test the intake systems PRESSURE 2) Role] EMI lalet= ie Walbro Corporation 99 2 = fe} o = w i a a =) fe) ra E 40 Walbro Corporation for proper operation. On a four-stroke engine, por fonning a kak-down testis quite helpful, On a tw0- sirokeengite, performing a vacuum test on thecrank: cease is necsssary, In the absence of these tests you ‘cannot be sire whether you are dealing with a carbu- Telor or an engine induction problem. Inthe absence ‘ofa leak-down geuge or a crankease vacuum pump, the follow ng tests can help pinpoint carburetor or intake problems: +A goo first estisvo spray some fuel into hie spark plug hole, reinstall the plug, and “ry to start the engine. Ifthe engine fires, jyoucan assume that ignition and comp sion are operstional + Next, spray somefuel intothecarb throat. Ifthe engine fies again, you can be pretty sure thattheproblem isin ihe carburetor, or at least the fvel system, Ifthe eagine still ‘doesn't Tire, you Will need to inspeet the intake system and the other components of ticengine, + Ifthe spark plug is wet even though the ignition is good, the engine is getting too much fuel 10 run, or the plug is wet with something other than fuel Sonowif you're sure iat he carburctoris causing the problem, you can begin to troubleshoot the carbure + Proper thoroughtroubleshoctiag can only be done in a systematic way, starting with the easiest things to check and moving on to the more difficult, On a carburetor, the eck list from easiest to more difficuk ‘may look ike this: 1. Mixture screw seitings 2. Feel level and quality (drain tank) 3, Fuel tank venung 4, Fuel filter (replace) 5. Throulo and choke linkages 6. AircleanerPressure Testing Pressutize the entire fuel system with the wunp andl gauge, You should gota pop-of and are Seat pressure. This checks the following things: fusl jie for leaks and soft spots; fuel pumps for sticking valves and plugged inlet screen: inlet needle for proper pop-off and re-seat ‘As you have the pressure tester hooked up to the fuel Line, crank the engine over. On each intake stroke, the needle on the 57-11 gauge should drop. This indicates thatthe metering diaphragm is allow ing the needle 10 open and air is passing through tie carburetor fuel passages into the throat. You may have to choke the carburetor o perfom this ts. Pop-off and re-seat pressures are not critical com: ponents of carburetor troubleshooting. You ar plac ing the carburetor in a very unnatural situation by pressurizing it with 30 pounds of sir Pop-off and re- scat pressures may vary by 10 oF more PST from carbaretor to carburetor. The important thing is that the needle does pop off at some point, and the re-seat pressures be10PSlorabove, This will ensure thatthe {uel pump pressure does notoverride the needle since the pump produces 5-7 PSI Refer to the troubleshooting chart in the back of this mana to help you determine the possible cause of aproblem, Detailed helow are some fue systems problems that are not specifically listed on the cha Hard Starting Hot Hit restart prolems can often times be traced to When presure sting the Ul system, you rood nal wal er the ret reac i pap oft Yourcenapanth inal reein by cranking the enigibe or ‘vapor lock inthe carb or Fucl line. Vapor lock eccurs "Sp iing the metering aaparagrtircugh ihe stvcaphare vest ew ‘tn ni edie r-sacts teow 10981 ct does hl reso, flow the when the fuel lines or the carburetor are heated above Mabe pa see normal temperatures after the engine is shut off, and the Liquid fuel turns to vapor. Inspect the exhaust and air shields for damage. Make ceriain the insulator blocks and gaskets are the proper ones for your engine. This problemcan be compounded by the ‘wrong season blend of fuel. A cold weather fuel will vaporize too easily inthe heat. Another heat related problem can result inthe fuel in die tank pressurizing the carburetor to the point of the needle coming unseated, causing carburetor leakage and engine Mood ing. This problem ean occur more rapidly with an alcohol fuet blend. A rich adjusted carburetor will und hot start problem by delivering even ‘more fue! into an already rich engine, Different en re various amounts of choke iostartup hol. Some will flood too easily when hot; others may require choking w draw a vapor lock through the arhuretor. Unfortunately, these insights into what Ukcengine “likes” can only come through experience with that engine SNILOOHSA1EGNOUL No Idle An engine that fais wo idle could be caused by several problems. Is the idle speed too low? Is ther g 01 the engivie? Poor crank seals oF poor vin the idle, Carburetor problems — Walbro Comoration 14(o} F = ° fo} == oH ii —_ a =) fo} iv EF 12 Walbro Corporation eeu following problems: dat voll nan the idle are: clogged we citeuits and ‘sion holes: misadjusied idle mixture serews ais Joaks a the carburewwr mounung gaskets, and leaking main nozzle check valves. A metering lever Set 160 high will cause the main nozzle to drip and pronluce anerraticy rich ideas will dhe wrong meter ing spring Poor Idle {A lot of poor idle problems can be ced w fuel pudding, Fuel puddling occurs when fue! vapor jeomes OuLOf suspension and forms pools of liquid gasoline inthe crankcase of 2 two-stroke engine, oF the intake vact. Some puddlingis inevitable, as some fuel will bc knocked ext of suspension by the crank shaft and connecting rod. The swirling of the fuel within the srankcase ean also lead to paddling. Pus: dling causes problems when th turned and the raw fuel is ingested into the combus- tion chaaiter. A ich idle mixture can syyravate Fuel pddling, 25 will a high metering levee, pressurized fuel tank, ora diny air cleaner. Usually 2 fuel pud- illing problem reeds to be comcted by a better internal enzine design, utthe problem is aggravated bby poor carburation ne is moved or Poor Acceleration Ifthe caiburctorhas an accelerator pamp, you will needa determine thatitis working properly. Refer to the Accelo-ator Systems section of this manual. Most engines accelerate off a slightly rich idle mixture. IF the idle mitre is adjusted forthe pecfectidle, that's probably to lean for goed acceleration, Ifthe meter ing leveristoo low, or the metering springs too stiff, the mixture will be to lean for acceleration Poor High Speed ‘The increased demznd for fuelat high speed opera tion can overload the capacity of a diry fucl system fo iulet screen, Soft fuel fines have a tendeney to collapse under the increased draw at high speed. A poorly veatilated tank will cause high speed fucl Starvation. sticky main nozzle valve oroneswollen fiom stale fuels will not allow gasoline through the high speed system. A governor on the carburctor oF ignition will give the effect of pooe high speed per formarice when the cagine overruns Carburetor Disassembly ‘Ninety percent of all carbureinr problems come fom dirt and fuel gums. Before disassembling @ carburetor, wash it thoroughly in clean solvent. A clean, wel-lighied working surface is essential we good carhurcuor repair. The following tools ill be ‘most useful atthe carburetor repair beneSoftJawed Vise Pen light Necdle-nose pliers Magnifying glass ASsL Screwdrivers Compressed air Spray carburetor Small Ballpeen hammer leaner 57-11 Prossure Testor 500-500 Tod! kit Toualy disassemble the carburetor, Use the illus- tuation in your catalog as a guide to ensure you've removed everything. Not every part shown on the ‘breakdown willbe included in your particularcarbu- rotor. The best cleaner for Walbro carburetors is a spray type carburetor cleaner. The pressure in thecan. works to dislodge dirt, and the chomicals aren't as caustic as the dip tank cleansrs. Ifa dip cleaner is used, all plasticand rubber mustberemoved from the carburetor, and the carburetor should not be soaked for longer than 15 minates. soe fo} Pd es) wo = ee] | fo} a a m a = = 5 Mixture Screws Inspect the tps of tho mixture needles; they should be free of grooves. A.ring youcan see is ek, but you showidn’t be able to feel it with your fingernail. Bo aware that ifthe needles are groeved, thei seats wil be ruined also, A damaged serow or seat resulls in t very sensitive needie. Ifthe earburctor seems hard to adjusalwaystoo rich or toolean the needles and the seats are probably ruined, Walbro Corporation 1314 Walbro Corporation — Fuel Pump ‘The fuel pump is generally trouble free, But here ae some problems that can arise. 1. The diaphragm cheek vals ean get stuck down by fucl gums and varnish, peventng fel flow through the exrbureter. 2. The crush ribs in the cover that seal around each chamber cen got damaged by rough reatment.allow- ing the fue. pump to leak or reducing its capacity. 3. ‘The machined surface where the check valves seal can get scratched or nicked; if this hppensthe valves rmay not held and pump capecity may be reduced oF the pump may empiy of Tac! during storage wequiing ‘excess cranking time to re-prime, Welch Plug Removal Removing the welch plugs is esontal fora thor ‘ough carburetor service job Remoring the welch plugs is best done with the Walbro S(0-16 tool. Hold the punch ata shallow angle to the welch plog an drive it through, If the ‘punch s not held a shallow angle i could damage the calibrated passages underneath ths plug. Spray carbureirsleaner through ie idiepassages under the plug or plate. DO NOT use a dnl or other tools to clean the passages, These hols are precisely sizes ‘and changng them - even a shousandda - will effect toe engine hake, Wiel, you ave Saisie das fl he passagesareclean, rinse thecarburctorinsolventand blow itd. Cirouit Plate Removal ‘The ckcuit plate will be held in by one or two screws, Undemeath the circuit plate willbe a gasket ana positly adiaphragm, Take your timeand follow the passages undemeath the plate and gasket. Make sure you know where the fuel is coming from and where it isgoing to, Some carburctor kitshave more than one drcuit plate gasket in them. Make sure you use the proper gasket for your carburior whon foas- sombling t, I yourute the wroag gasket, will result inthe lossof fuel flow 1 one or bod citits If your hurctor had a circuit plate diaphea ‘Euheciscuit plates or welch plugs arc leaking, .willypasstho mixtureserewsand te carburetor will rua rich.Main Nozzle Check Valve There sre two types of main norzles on Walbro ‘bureiort: the mechanical seal and the capillary soal, The mechanical seal chock valves can all be checked quite easily, Locate the hole that supplies fuet to die main nozzle, This will wenerally be close 1 ihe igh speed needle. Place the end of a piece of primer hose over the tuel hole; make sure the high speed needle is tumed outa few turns, You should be able 10 easily blow through the valve into the carbaretor throat, but not able 1 suck air back as easly. 5 I the hole is hard to reach with the hose, you ean alo plug the supply hole with your ingerandhold tie hase over the main nozzle needle hole. Ifthe check. valve tests okay, no further action is needed on it Tre capillary screen seals rely on the capillary action of gasoline against a fine wire screen tokesp ait from coming buck through dhem at idle, Since there is no mechanical seal on these valves, they cannot be tested with the primer hose. Also, the capillary screen is susceptible to clogging with debris, that has managed 10 pass through the inlet screen, ‘Therefore, its recommended that the welch plug or plug over thescreen be removed sothescreen can be cleaned and inspected. Refer to the carburetor pats listo see if the earbureior has 4 check valve = = Fa 2 9° SI at re ui fe] = ui fe] z < 5 ‘S < mi Cup plug over sreen: pa Walbro Corporation 15‘Cup plug removed, copllory seroon visio. 16 Walbro Corporation Reinoving the cup plug to gain access to the check Valve isbxstdone with a #8 botioming ap ora Saiz ser screw, Screw the tap int ue cup plug, then pull the tap and plug straight out. Walbro uses a number of main nozzle check valves. ‘They are town here along with the proper method of seevicing bem. NOTE: efore servicing the check valve, remove the high speed needle, “The mos preslominant check valve syle in produc- tion now tas a capauis check valve. Theae are all- contained and arepressed into the carburetor body. If they needio be replaced, they are smnply pressed on through io the carburetor throat. Some carburetors havea long tbe nozzle; these must be pressed back foutof the thrnat with a it blade screwdriver. Older rodet carburetors such as the HDC contain a throe pikce chock valve system This consists of a chock vahe ise, abrass retainer anda debris sercen. ‘The setsincr is removed with ihe side haznmer puller ££500-501 in the 500-S00 too! kt, Some HDB carbu- iors use. similar system Dut use the sereen as a capillary aMany WA model carburetors use a similar check ‘valve retained witha smaller cap. Thisca od ‘withthe pin punchstyle ols inthe tool kit, Too! 500- 2 is used to remove the ring over Une check valve 3k, and SOD-14 is used to reinstall it Circuit plate style carburetors may use a simple fapper style check valve incorporated into a small diaphragmunder the circuit plate. Take careto install the correct cireut plate diaphragm, as the wrong one ‘can Shut off all the fuel through the carb, ‘The check valves are gencrally trouble free, but ey will get cloggedup with {uel gums and shouldbe removed before dip tank cleaning, Inlet Seat Scak s cotton swab in carb cleaner and use it to remove fue! gum from the inletseat. Do pot insert any hard tools into the seat as they can damage it On a carburetor that has had a lot of use, eventually the inlet seat wll become worn. When this happens, the needle will nolongerhold pressureandthe carburetor must be replaced. During cleaning, spray carburetor cleaner through all passages toensure they are free of obstructions, SATIVA MOSH 31ZZON NIV Walbro Corporation 17REASSEMBLY 18 Walbro Corporation Carburetor Reassembly To begin reassembly, install the circuit plate or new with pags, Cay the welch plug into iss well; apply thin ingf na polish aroand te eas ofthe lug a dive it lat, Make str the welch plugs are Given fla or they may interfere wi dhe metering diaphragm movemeat. Wipeal trail poih oi te pig. cosavca this ringaround the eg. The sealant dels as an extra measure fo ease the pg dowsm't lea. IF the plug leeks you will notice that he dle needle booomes less effective, Tool SDD-15 is the proper ol for weieh piu instalation If tho carburetor tas a cup plug over the main nozzle, be careful to a0 install it too dovoly into the main nozzle well Uf pressed into far, itcan restrict, the flow offic! from the tip ofthe high speed needle. Presse cup plu i jst Far enough so itsupper cu is even with the mecering chamber floor, Next, reassemble the fuel pump, Install the indot sereenta theproper depth, installnew, criginal Walbvo ‘askes and diaphragms. Remember that the pamp ‘iaphragm goos of next io the carburetor bea. NO» Licethoerush ribs on he undesside ofthe pump cover. ‘Thesearc essential for good sealing and should noi be damaged. Install the inot needleymmetering lever and spring. Setthe meteringleves heightusing the 500-13 gauge, “Tnis hoight is very important so make sare it is ccomrect, I you are using an older gauge on a WZ or WY caburcior, use the gauge ib marked for he WA, and WT carburetors,Final Pressure Testing lace a small amount of fuel in the inlet needle ‘well, Now pressure tas the carburetor again with the 57-11 gauge. Obsorve the pop-off and re-seat pres- sures. I'he casbureior does net hold pressure, m= ‘merse iLin selvent to determine where itis leaking, Sal bubbles around the fuel pump cover are okay, but you should not get bubbles from undes the inlet needle until ihe needle pops off [fitis okay, continue assembly B'] EY ba o cn = Es] a eI GB | 2 9 ‘Sma bubble athe flu gaskat are not har. Walbro Corporation 1920 Walbro Corporation — Insiall dhe metering gasket and diaphragm IN THAT CRDER. The metering diaphragm cover has vont Hole cither in the center or on the side. I's importact to install the cover so the hole 1s facing away from the engine fan. This way tho ble does not ‘gel Saw¢ust blown into it, I the fan does not blow across the carbatetor, insiall dhe cover with the hole facing the nommal downer position if you have a choice, "Your last step is 19 install and preset the fuel needles, LIGHTLY wenche needles inunil ey seat, then back them oui 1 1/2 wens. This scuting will be richer than the finaladjustmsert, Final adjustrent will bedone with thoenginte running. Someengine mana- facturers recommend a preset other tham | 1/72 cums, if so, follow their direction Final Adjustment Idle mixture: ‘The idle Fuel mixture is usually adjusted Drst. Start the engin and Jt it reach its normal operating tem perature, Begin slowly weningthe idle mixtureserew clockwise, As you tum it in, the engine speed will increase and then start to decrease as the minture gets leaner, Note the nezdle position atthe point wha the engine speed saris to decrease; this is called the Kean Arop-af point, Back thorecedle outand the speed will again increase as the mixture passes through opti- imum teveand righ. Now the positon of the needle ‘when Lie speed agai stars todcerease; this isthe rich drop-oft point, Your final needle s21ng is halfway Dotween the rich end the lean crop-oft points. Once. ine mixtureisse, the idle speed needs to beadjusted, Soc he ale spocd atthe recommended R.P.M..or just balow cluich engagement. High Speed taxture: ‘Thebigh speed mixtures adjusted much the same way, Wil he engine at wide-open throttle, find the ‘rch and Jean drop-off points, and set the mixture ‘beoween them, WARNING: REMEMBER THE EFTECTS OF RUNNING AN ENGINE LEAN. RUN THE EN- GINE FOR ONLY AN INSTANT AT THE LEAN DROP-OFF POINT, Ithceagineseomstorun rich athigh speed whenaat tinder a Joal, check 10 see if it has a carburetor ‘governor. See page 0 forinlormation on Walbro ca buretor governors. Once the carburetor is adjusied, re-check the ile speed and make sure the engine accelerates smoothly. (Fir siumbles on acceleration, corich the idle mixture slighly. If poor scceleration stil occurs, determive if the carburetor is equipped ‘vith an accelerator system and that itis working properly.Barrel Valve Carburetors ‘The thearies of operation of the barrel valve carbu- tor is very similar w that of the buserfly valve carburetor, Du the actual operation is quite different. In the buttery valve carb, the throttle plate con- uols he ar flow into tie engine. To increase engine. speed and power, more air is admitted to fill the cylinder. Inordee to maintain the properai/fucl raéo forengine operation, the amount of fuel mustinerease fr decrease in proportcn to the amount of air. At highcr air volumes the airflow thvough the venturi is adequate to daw fuel out of the main nozzle. The ‘more air, the more fuel in fairly equel proporticns. At lower engine loads, the engine is no: drawing 2 lot of sir. Tn faet, the air lows through the venturi easily without drawing fue! outof wie main nozzle, AL these. Jow engine loads and speeds, we must provide fuel olivery at other points with higher manifold yac~ tuums, These over delivery points are the idle and progression holes, where higher vacuum is creatd by the position of the throule plate, ‘The bare! valve carburciors use amechnical con- woloverthefvelflowing mio the intake air rather than relying on teair flow alone to contrat il, The barrel siill regulates the air flow like 2 theotle plate, but instead of foel entecing the air stream at the main nozzle and three or Four progression holes, the fuel enters the air steam from only one spot - tho fuel owe. Since the bartel resricts the air flow bowh before and after the main norzle. the main rozzie is always acted upon by the same amount of vacuum, essentially a variable venturi. A moveable needle in the fuel nozzle controls the fuel flow at all throttle sculings. The needle movesinto the fuel nozzleat low throtde and out of the nozzle at wide-open throw. ‘The needle movement is controlled by the threttle ramp. Theadvantage of tebarrel valve design isha itprovides foravery even air/uel mixture throughout all Uwoule seaings. Presently, there are wo model classifications in the barel valve line: the WY"s and the W2"s, The W2"s are characterized by the pecs ence of of a built-in air cleaner, and tne ais flow through the carburetor makes a90-dogree bend. The WY's have the most diveisiy. There are currently eight WY models: WY. WYE, WY, WYK, WYI WYM, WYP, and the WYF (which is a Moat-siyle carburetor). The WY 'sall have the fuel pump and the metering diaphragms stacked on one side ofthe carb ody. Some of the WY"s have meial bodies, some have plastic bodies. Most are fixed jot carburetors, butthe WZ and some WYK’s have adjustable rain Jet. Despite this variety, the WY’s all operate in ‘much the same way. As thethrotle Ieverisrotated by the ote cable, Ux hole within the base! comes into alignment with the hole threugh the carburetor body. Atthesame time, thethrowe pin follows up the ramp under the throtde lever. The pin, rising up the ramp, lifts the barrel and the fuel needle so thatthe needle exposes more of ue slot in the side of the nozzle tothe air steam, oO > a es) m ia < 5 4 ul fe) 5 a oD e ee) ru | fe) os) on Walbro Corporation 24The Operation of the WY ‘The fuel pump passages are cast into the body. Ceankeease impulse is dehvered to the fuel pump diaphragm through the passage tothe lower right of the throat The fixed jets pressed into the body and scaled wth an O-ring. Notice how the tabs of the pla, gasketsand the diaphragm steck up in a stair- step etiom asthecarb is assembled, The pump cover is the floor of the metering chamber, It contains the inletsereen, the inlet needle and seat and the meter- ingleverandspring. Themetering gasket, diaphragm, and cover complete the carburetor assembly. Fuel IMPLLSE| Take ain) Tr operation, the fuel is drawn into the ear throat from the fuel nozzle, through the jet, and actully travels up through the center of the pump diaphragm stack, Fom a bole under the metering lever. The engine vacuum draws the metering diepinragm down, ono hemetering lever, which overridesthe metering. springallowing the inlctncedle wolif.ofTitsseat. The fuel is pashod through the inlat seatby the fuel pump. 22 Walbro CorporationThe WZ Carburetor ‘The WZ is unique in Uue way the air ows through {iL ILalsohas an adjustable high speed mixture needle and an integral air cleaner. The fuel pump and meter~ ing diaphragm are on separate sides ofthe carb body. (On the WZ, the fuel pump cover also houses the prime: system, wet | SHINaS ZM | operation, de fuel is dcawn from the nozzle into the air swear. The fue! comes from the metering chamberthroughthe nozzlecheck valve (which works, ‘with the primer and is pressed into the floor of the nietering chamber). Fuc! drawn from below the me- tering diaphragm allows tho inlet scedle to open and the Tuel purnp ref the chamber, Walbro Corporation 23” AY 2 my = = ® a] 5 a < 5 = Wu i =) i) a t CG) ES 2 > I vi rs Ps < o 24 Walbro Corporation — Adjusting the Mixture tle: Some of the barrel valve carburetors have aa idle amixiure Limiter screw on top of the trots lever. Before ajusting the idte mixture, the fimitée should be in the cnter of its uavel. This outor screw makes very small mixture aijustmenss, Many WY catbure- tors do not have this limiter. IDLE MPXTURE LIMITER ‘AT CENTER OF ITS TRAVEL The lel newdle adjustment screw is Loeated down inside tie center of the barrel and may be covered with aplastic capormay even besealed with silicone. Lr the serew has not been distarhed, adjustments are senerally not needed. If you have no idea where the serous is presenily set, preset it hy wuming it all the ‘way out unl che threads disengage, then beck $ turns for the WY Series or back 6 tums for W2’s and 15 ums forthe WYO, WYK, WYL, and WYE, Tur te idle speed serew in until the carbursior isa approxi imately hall throw. Star dhe engine and adjust the ilerixiurescrewtoobiainthe highest RPM. Allow ‘the engine 1 waren up and then elose the idle speed screw down to 3000 R,P.M,, oF the point just before Clutch engagement. Adjust the rixtune to ths highest R.P.M. again, then tura the minture serew um add tional 1/ win counter-clockwise, (Couater- clockwige=richer) High Speed: ‘The WZ's and afew of the WY modelshawea high spent mixture sere, The preset iS 1 1/2 urs. At ‘wide open throttle the mixture should be zljusta 9 the midpoint between sich and Kew, ‘Vhors are several different fixed main jets avail- ableforthe WY. If,dacto your operating altitude you need! toehange jet sizes, look in the jet section of the price List forthe various sizes.NOTE: Some WYK carburetors have anadjustment screw that will producea “richer only" mixture; you ‘may not olive lean dop-olf on inese carbuctos. Air Purge Systems “The air purge is often mistaken for a primer, But while a primar injscts the fuel ina the carburetee throat, an air purge sysiem simply removes the air from the ful passages so the carburctor and felines ar fall of ful. Airpurge systems are heing installed Conmany Wale carburetors 1 premoteeasier start ing ofthe engine ‘The Heart of the air parge systema is the bulb. The rubber bulb is generally mounted on the carburetor, but it can be mounted sspaately ifthe customer so desires. The bulb works in eonjunetion with a series ‘ofmne-way check valves. on some alder systems, the the check valves aro two clear plastic Uses sith springs koldirg them closed, These valwesarelocaed dlizelly below the bulb. Depressing the bulb forces air through the di. charge valve and out a tube back to the fuel tank. ‘WYK with enrichening mibeture serev. 2 Ey u ¢ E g) cu) oO < Ca 4 ful = Cm} Walbro Corporation 25PRIMER SYSTEMS Derossing the Bub orces ar oul he overiow lube 28 Walbro Corporation Releasing the bulb closes the discharge valve and ‘opens the inlet valve, The vacuusn uavels tough & channel and iniothe meicring chamber, Hezeit draws down cr Ihe metering, diaphragm, opens the inlet nocale, and draws fuel from the nk rough the fue} puny. (Once the bulb is full of fuel, all dhe air has boon removee from the fuel system. One critical compo ‘nent to nis sysizm is the check valve located before thenezae, Ths prevents air from coming it rough, the tual rozvle wen the bulb creates the vacuum in themotering chamber. A barrel valve carburetor foes. not need a check valve atthe nozzle otvenwise. Newer air purge systems use rubber double- acting check valve ia place of the 1wo spring loaded dise valves,The butterfly valve carburetor air purge system works the same way as the barrel valves. Howeva the indcieck val yepreventa ei flow bach into the mesering chamber from both the high speed and the ile circuits, These carburetors will ill have, 8 separcte main nozzle check valve like all other butedty valve carbaretors. Primer Systems Presaly only WZ and some WYK models have river syste. The primer systom works in mach the same way asthe air purge but instead of simply pumping the fuel beck Lo the tank it alse pumps fuel into eilfer a stares box ora staner wick. The tater ‘wick porons foam wiek that ser the fue front ‘de prinerand makesitavaitateo theengine atstart up. Theone possible probem withthe primer system is the potental for floading the engire ifthe bulb is press t00 many tines. To overcome thi problem, Walbro offers cazbuetors with a start box. The starter tox sores a metered amount of fus] so when the starr baton is prossed, fuel is éelivered to the aiarcr vick, On W2's the sarter wick is loeted tichind he intake cup. WY K earburotors use a primer systrn with the stair wiek under the botiom ofthe arte. he WYK’ wih stat boxes have an addi- onal soring loaded diaphragm that pressuizes the fuel being put ito she starr wick."a ha BUb rela to shape rane Ts Though he fel pomp and Therrlorig chanvertott tebe. Troubleshooting ihe primer and ar purge systems is generally only a mater of cleaning and servicing the check valves and the bulb. The bulb should be pliable and free of cracks. If itis stilt or brite it will not function, The chock valves ean gtstuck with fust um or debris. If the bulb fects Tike it cannot be depressed, tne discharge valve orthe reuumn line back tothe fuel tan is plugged or kinked. (Fthe bulb does tot spring tack into shape, Ue inlet chock: valve is probably stuck closed, orthe fucl line is restricted. IF the bulb constantly fills with air instead of fuel these could be a leak in the fuel system, or the discharge ‘check valve or the nozzle check valve is stuck open. Any defect hat prevents the carburetor from geting fuel to the engine will also prevent the air purge or primer from working (with the exceplion of the novle check valve) iit is stuck closed, the eagine ill not ra ba We primer will wor. Ii is stack : ‘open, the engine will work but the aiepurge won't If Trenaxtline ie bulbs dopossea, fal is pushed totha sar tar and yOu suspect the check valve on a butterfly valve Sth vertow. 09 tpatiors tins te ats sor, Howe tothe casburetorissiicking open and causing the bulb tofill ‘with air, shut off both needles and then work the air ‘purge-Ifthebalh now fills with Ful, the chock valve feeds be cleaned or replaced. Toreplace it simply serewa sheet metal scrow iniothe centerholcand pull tne whole assembly out, then press.a new one in. To test any check valve, determine the proper direction ‘of flow through the check valves and test for it with the primer bose (like you did widh whe main nozzle check valve) hs} Es = m a n < (7 = ful = 7) “T3uTT0N ‘Gnstavorbox acupped crrurtor, the faliedlvatod i the wick ony 7 Welbro Corporation 27Accelerator System: “Thereare tee styles of accelerator purnps found cn Walbee diaphragm carbuctois. All ec ascused {o provide a exira shot of fuel to ennch the mixture ‘when thethcotleisfrst opened. The advantage of the sxceleruoe system is hati allows thee mixture 10 ‘be sotatoptimum, rather Ua lightly ick, allowing neengize idle beter. Piston Pump: ‘The piston pump system consists of a small brass piston in a cylinder, dilled into the carb body. The piston isheld intoa flat spot on the throte shalt bya spring, When the throtdeis opened the piston s ited ‘Outof the flat spox and pressurizes ihe fuel behind it ‘The fuel is forced through a channel and is injected. {nto the main nozle ar metering chamber. ou WIDE OPEN THROTTLE Crankcase impulse: ‘This aystem usee the pressure pulses from the crankcase (© pressurize the metering chamber. A roscure passage (similar to tae one thatruns the fuel pump) is channeled up to a hole in the carbureior Ca) ty. When the theses opened ote ecugh he thoi shaft lines up with a hoe in the body This allows he puss to travel imo the chamber onthe ry ‘side of the metering diaphragm, forcing the dia- ‘hragm down and allocing the inlet needle w open me WIDE OPEN THROTTLE (22) = ir = o Ee a [nag iS 4 (eat wi a rm 9 (3) ia 28 Walbro Corporation __ aBoot Style: This system uses a small rubber bladder 1 hold a shot of fuel. The inside ofthe bladder isconnected to the metering chamber, or dircely to the carburetor Uroat As in the impulse style acceleraor, a hole leads rom an impulse source through the centerof the throtle shaft and into a small brass cap surrounding the cubber boot. Whea the thrgtile is opened, the impulse pressure is allowed to flow around the out- sideofthe boot collapsing itand forcing fueloutof the inside of the boot and into the carb throat. ‘Troubleshoouing the accelerator sysiem is gener- allyamatter of keeping the passages clean. IF you are having trouble with engine acceleration, check for an aceclerator pump anid make sue i's operating. P= 9 i?) mm iT: m = a fe} Ee oO < oO a m SS 7) Walbro Corporation 294 fo} Fe i S fe} o 30 W foro Corporation, Governor Systems The governor isanouker option available w Walbro cated in 2 running engine. The goverror consists of a spring holes 2 ball against @ seat. When te engine ‘ceeds its goveme speed, the vibration of te ball cvertdes the spring, When bis happens, fue is alowedio bypass te talland flows directly fromthe -mtering chamber into tecasb trot. Thevich mixture causes the engine to slow dow, Generally there isa service needed on the gover re system IFyou canrot get the mixture tales out mike sue the geveror hulls nat stuck open, Keep Jnmmind thatthe engine will act rich a customers. It works olf bie vibrations os its governed speed, so you will not boable loan it at no-load, wide-open theoille, To adjust the high syed mistureon a governedengine you will baveto fond down dheengine to aujus the high speed snixuire buxcause onmany engines ihe governed speed can be Feacted before the main nozzle iy delivering fuel. This style governor system has also been incorpo: ‘ae inio tne main nozzle on seme carburetors,‘The proper tools ad efficiency and profession lism the carburetor repair job. The 37-11 pressure tester and the 500-500 tool kit are also available asa pockage: order the 400.595 from your distributor to receive both. Any of the tools in the 500-300 kit are alo avsilable separately from your Walbro distribu- lor. The 57-11 pressure gauge pump caa be rebuilt, using the K1-Gauge rebuild kit ae YY a “00. NO. £00501 = TOOL NO S008 Toot so Toot no 50082 Jootno woos — “500500 ToolKit ~ - Walbro Corporation 31Walbro Engine Management Aftermarket Division 6214 Garfield Stree Cass City, Michigan 48726-1325 Telephone (989) 872-2731 G-1022 FAX (989) 872-3090