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FUEL SYSTEM &
CARBURETION




                                      3
                                      B

 FUEL PUMP
 RECIRCULATION SYSTEM
 REED VALVE ASSEMBLY
 AUTO ENRICHNER




90-831996R1 JUNE 1996   FUEL SYSTEM   3B-–1
Table Of Contents
                                                                        Page                                                                    Page
Fuel Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . .    3B-1       Inspecting and Installing
   General Information . . . . . . . . . . . . . . . . . . .            3B-1           Reed Block Assembly . . . . . . . . . . . . . . 3B-9
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3B-2    Reed Plate, Intake Manifold
                                                                                   and Auto Enrichner - 90/95 HP . . . . . . . . 3B-10
Removing/Disassembling
   Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . .      3B-2    Reed Plate, Adaptor Plate and
                                                                                   Auto Enrichner - 120 HP . . . . . . . . . . . . . . 3B-12
Assembling and Installing Fuel Pump. . . . . . .                        3B-3
                                                                                Auto Enrichner . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-14
Fuel Pump Exploded View . . . . . . . . . . . . . . . .                 3B-5
                                                                                   System Description . . . . . . . . . . . . . . . . . . 3B-14
Fuel Recirculation System . . . . . . . . . . . . . . . . .             3B-6
                                                                                   Testing Auto Enrichner . . . . . . . . . . . . . . . 3B-14
   System Description . . . . . . . . . . . . . . . . . . .             3B-6
   Testing Fuel Recirculation System . . . . . .                        3B-6
Fuel Recirculation System 90/95 HP . . . . . . . .                      3B-6
Fuel Recirculation System 1995 120 HP . . . .                           3B-7
Fuel Recirculation System 1996 120 HP . . . .                           3B-8
Reed Valve Assembly . . . . . . . . . . . . . . . . . . . .             3B-9
   Removing and Inspecting
       Reed Valve Assembly . . . . . . . . . . . . . .                  3B-9




3B-0                                                                     FUEL SYSTEM                                   90-831996R1 JUNE 1996
Downward motion of the piston forces out the fuel
                       DANGER                          pump diaphragm, closes the inlet check valve (to
                                                       keep fuel from returning to fuel tank) and opens the
FIRE AND EXPLOSION HAZARD. Observe fire
                                                       outlet check valve, forcing fuel to the carburetors.
prevention rules, particularly NO SMOKING.
Before servicing any part of the fuel system,          Checking for Restricted Fuel Flow
disconnect electrical system at the battery. Drain     Caused by Anti-Siphon Valves
the fuel system completely. Use an approved
container to collect and store fuel. Wipe up any       While anti-siphon valves are helpful from a safety
spillage immediately. Materials used to contain        stand-point they clog, may be too small, or they may
spillage must be disposed of in an approved            have too heavy a spring. The pressure drop that oc-
receptacle. Any fuel system service must be            curs with these valves can create operational prob-
performed in a well ventilated area.                   lems and/or powerhead damage by restricting flow of
                                                       fuel. Some symptoms of restricted (lean) fuel flow are:
FUEL LEAKAGE FROM ANY PART OF THE FUEL                 1-Loss of fuel pump pressure
SYSTEM CAN BE A FIRE AND EXPLOSION                     2-Loss of power
HAZARD WHICH CAN CAUSE SERIOUS BODILY                  3-High speed surging
INJURY OR DEATH. Careful periodic inspection of        4-Preignition/detonation (piston dome erosion)
the entire fuel system is mandatory, particularly      5-Engine hesitates upon acceleration
after engine storage. All fuel components,             6-Engine runs rough
including fuel tanks, whether plastic, metal, or       7-Engine quits and cannot be restarted
fiberglass, fuel lines, primer bulbs, fittings,        8-Engine will not start
swelling, and must be inspected for corrosion.         9-Vapor lock
Any sign of leakage or deterioration necessitates      Any type of anti-siphon device must be located be-
replacement before further engine operation.           tween the engine fuel inlet and fuel tank outlet. A
                                                       method of checking [if such a device (or bad fuel) is
                                                       a problem source] is to operate the engine with a sep-
Fuel Pumps                                             arate fuel supply which is known to be good.
General Information                                    If it is found that the anti-siphon valve is the cause of
                                                       the problem, either 1) replace the anti-siphon valve,
Fuel Pump Description/Operation                        or 2) replace it with a solenoid-operated fuel shutoff
The fuel pump is a crankcase-pressure-operated, di-    valve.
aphragm-type pump. Crankcase pulsating pressure        Testing
is transferred by way of a passage (hole) from the
crankcase to the fuel pump.                            Install clear fuel hose(s) between fuel pump and car-
                                                       buretor(s). Run engine, and inspect hose(s) for air
When the piston travels upward a vacuum is created
                                                       bubbles. If air bubbles are found, see “Air Bubbles in
in the crankcase. This vacuum pulls in the fuel pump
                                                       Fuel Line” . If air bubbles are NOT found, see “Lack
diaphragm, the inlet check valve (in fuel pump) is
                                                       of Fuel Pump Pressure”.
opened fuel is drawn into fuel pump.




90-831996R1 JUNE 1996                          FUEL SYSTEM                                                 3B-1
Troubleshooting Fuel Pump                                  Removing/Disassembling
                                                           Fuel Pump
        PROBLEM: Air Bubbles in Fuel Line                  1. Loosen screw on sediment bowl.
       Possible Cause           Corrective Action          2. Remove bowl from pump body.
Low fuel in tank.            Fill tank.
Loose fuel line connec-      Inspect and tighten con-
tion.                        nections.
Fuel pump fitting loose.     Tighten fitting.
A hole or cut in fuel line. Inspect condition of fuel
                            lines and replace any
                            found bad.
Fuel pump anchor             Inspect and tighten all
screws loose.                screws.
Fuel pump gaskets            Rebuild fuel pump.                         a
worn out.
       PROBLEM: Lack of Fuel Pump Pressure
                                                           a - Screw
       Possible Cause           Corrective Action
                                                           3. Remove gasket and screen.
Anti-siphon valve.           Refer to “Checking for
                             Restricted Fuel Flow
                             Caused by Anti-siphon
                             Valves” preceding.
Air in fuel line.            “Air Bubbles in Fuel
                             Line” preceding.                           a
Dirty or clogged fuel fil-   Clean or replace filter.
ter.
Dirty or clogged fuel        Clean or replace pickup.
pickup in fuel tank.                                                    b
Worn out fuel pump dia- Rebuild pump.
phragm.
Defective check valves       Rebuild pump.                 a - Gasket
in fuel pump.                                              b - Screen
Pulse hole plugged.          Remove fuel pump and
                             and clean out hole.
Diaphragm gasket dis-        Align or replace gasket
torted or out of place.      as necessary.

Special Tools
        Description                Part Number
Hose Clamp Pliers            FT-8900
RTV Sealant                  92-90113--2




3B-2                                                FUEL SYSTEM                     90-831996R1 JUNE 1996
4. Remove and disassemble fuel pump fitting,                               6. Replace fuel pump check valves as necessary.
   screws and washer, nuts, fuel pump body, booster
   spring retainer, booster spring, diaphragm, gas-
   ket, spacer, and spacer plate gasket.
                                                                                                    c
                              c                                                           b
                         i                            j
                 h                                                                    a


                                                          g                                             d

                                                                                               e
           b                                                               a - Center Check Valve           c - Gasket
                                                                           b - Second Stage Check           d - Screws
                                                                               Valve                        e - First Stage Check Valve
                                                          e
                                                                           NOTE: Removal of the second stage check valve
                                                  f                        may cause permanent damage to the pump body,
                                                                           therefore, if replacement is necessary it may be nec-
                                  d                                        essary to replace the pump body.
                     a                                                     7. Replace bowl gasket, fuel pump body gasket, and
                                                                              center check valve gasket.
a   -   Fuel Pump Fitting             f   -   Booster Spring               IMPORTANT: Replace all worn and/or damaged
b   -   Screw and Washer              g   -   Diaphragm
                                                                           parts.
c   -   Nut                           h   -   Gasket
d
e
    -
    -
        Fuel Pump Body
        Booster Spring Retainer
                                      i
                                      j
                                          -
                                          -
                                              Spacer
                                              Spacer Plate Gasket
                                                                           Assembling and Installing
5. Test fuel check valves by lightly pressing on plastic                   Fuel Pump
   seats.                                                                  1. Install booster spring and retainer.
S Be sure check valve seats when tension is re-
  leased.                                                                                                                         b


                                                                                                                                 a



                                                                           a - Spring
                                                                           b - Retainer
                                                                           2. Position diaphragm and gasket on pump body.




90-831996R1 JUNE 1996                                               FUEL SYSTEM                                                       3B-3
3. Compress spring using a putty knife. Install screws   6. Install fuel hoses.
   in pump body.
                                                                                                     b




     a                                                                                c
                                        b                        a

                         a                               a - Fuel Outlet Hose
a - Long Screws                                          b - Fuel Inlet Hose Connected to Sediment Bowl
b - Short Screws                                         c - Pulse Hose

4. Install spacer plate, nuts and gasket.                7. Install screen in sediment bowl. Install sediment
                                                            bowl on fuel pump.
                                                                                      a

                                    b
         a


                                                         a - Screen - Edge Turned Toward Engine
                                     c
                                                         8. Install gasket on pump body.


a - Spacer Plate
b - Nuts
c - Gasket

5. Position fuel pump assembly on transfer port cov-
   er. Tighten screws securely.
S Apply sealant (p/n 92-90113--2) to threads of fit-
  ting. Install fitting.                                                     a
                                                         a - Gasket, Aligned On Pump Body Keyway




               a


a - Fitting



3B-4                                             FUEL SYSTEM                              90-831996R1 JUNE 1996
IMPORTANT: Position sediment bowl with hose
fitting at the 4 o’clock position.




                                         a




a - Hose Fitting At 4 O’Clock Position




Fuel Pump Exploded View




                                              RTV Sealant
                                              92-90113--2




90-831996R1 JUNE 1996                        FUEL SYSTEM    3B-5
Fuel Recirculation System                                  Testing Fuel Recirculation System
                                                           1. Test for proper air flow through check valves as in-
System Description                                            dicated by arrows.
At idle, unburned fuel collects and puddles in the
crankcase behind the reed valves. The recirculation
system is a means to route this excess, unburned fuel
back to the combustion chamber.
One way check valves are located on the crankcase
cover, typically below the carburetors. Crankcase
pressure forces the puddled fuel through the check
valves. A hose connected to the check valve routes
the fuel to the transfer port cover, whereby the fuel is
introduced back to the combustion chamber.




Fuel Recirculation System 90/95 HP




3B-6                                               FUEL SYSTEM                          90-831996R1 JUNE 1996
Fuel Recirculation System 1995 120 HP




90-831996R1 JUNE 1996     FUEL SYSTEM   3B-7
Fuel Recirculation System 1996 & 1997 120 HP




3B-8                     FUEL SYSTEM           90-831996R1 JUNE 1996
Reed Valve Assembly                                  Inspecting and Installing Reed Block
                                                     Assembly
Removing and Inspecting Reed Valve
                                                     1. Inspect reeds for any chipping or cracking.
Assembly
                                                     NOTE: The reeds are not serviceable, replace reed
                          WARNING                    block assembly if any discrepancies are found.
Always disconnect battery and remove spark           2. Inspect reed opening. Replace reed block assem-
plug leads from spark plugs before working on           bly if reed is standing open more than .010” (.254
motor.                                                  mm).
1. Remove attenuator cover.
2. Remove carburetors.
SEE CARBURETOR SECTION FOR MORE INFOR-                         a
MATION
3. Remove auto enrichner.                                          b
4. Remove recirculation hose from manifold.                        c
5. Remove bolts securing manifold assembly to                       d
   crankcase cover.
6. Remove manifold assembly from cylinder block.
7. Remove reed block assembly from reed plate
   adaptor.

                                                     a   -   Maximum Opening .010” (.254 mm)
                                                     b   -   Reed Stop
                                                     c   -   Reed
                                                     d   -   Reed Block
 a                                                   3. Clean all gasket surfaces.
       b
                                                     4. Using new gaskets, install reed block assembly to
           c                                            reed plate adaptor.
                                                     5. Using new gasket, install manifold and reed plate
                 d                                      assembly into cylinder block. Secure assembly to
                                                        cylinder block with screws.
                     e                               6. Install auto enrichner.
                                                     7. Install recirculation hose to manifold.
NOTE: 90/95 HP Shown
                                                     8. Install carburetors.
a - Reed Block Assembly      d - Gasket
b - Gasket                   e - Manifold            SEE CARBURETOR SECTION FOR MORE IN-
c - Reed Plate Adaptor                               FORMATION
                                                     9. Install attenuator cover.




90-831996R1 JUNE 1996                         FUEL SYSTEM                                             3B-9
Reed Plate, Intake Manifold and Auto Enrichner - 90/95 HP

                      1
                           2


                                    4




        3




                               5
                                    6
                                         7
                                               8    9

                                                         13
                                                              14    15
                                        10                               16 17
                                          11       12

                                                                                           18
                                                                                      19

                                                                          19
            26
                                                                          13
                                                                                 20
                                                                                      13
                               23
                 25   24
                                                              13
                                                                    21
                                                    13
                                                               22




3B-10                               FUEL SYSTEM                      90-831996R1 JUNE 1996
Item   Qty.                             Description                             Torque
                                                                       Lb. In.   Lb. Ft.   N·m
  1      3     Reed Block Assembly
  2      1     Gasket (Top)
  3      2     Gasket (Center/Bottom)
  4      1     Adapter, Reed Plate
  5      1     Gasket, Intake Manifold
  6      1     Manifold Assembly, Intake
  7      8     Screw (1/4-20 x 1”)
  8      6     Stud (5/16-18 x 1-1/4”) With Dri Loc
  9      6     Nut (5/16-18)
  10     1     Elbow
  11     6     Screw (1/4-20 x 1-1/2”)
  12     2     Fitting
  13     6     Clamp
  14     1     Hose, Molded (Top) Connect to Upper Manifold Elbow
  15     1     Bracket
  16     2     Grommet
  17     2     Bushing
  18     2     Screw (M6 x 30)
  19     4     Washer
  20     1     Hose (4-3/4”) Connect to Middle Carburetor
  21     1     Auto Enrichner
  22     1     Hose, Molded (Bottom) Connect to Lower Manifold Elbow
  23     2     Fitting
  24     1     Clamp
  25     1     Stud (1/4-20 x 1-1/4”) With Dri Loc
  26     4     Screw (1/4-20 x 1-1/4”)




90-831996R1 JUNE 1996                           FUEL SYSTEM                                      3B-11
Reed Plate, Adaptor Plate and Auto Enrichner - 120 HP
                       1
                                             2
                                                                        7
                                                                                        8
                                     3
                       1
                                     4             4

                       1


                                         6         5
                       1
                                                                                  9




                           13

             25

                  24


              23
                                                                             10

                                                                        11
             22                                               12
        21
                                                        13

                  20
                                                   17
                                                        16
                                                             15
                                                                   14
        19
                                15
                                     18




3B-12                                            FUEL SYSTEM                      90-831996R1 JUNE 1996
Item   Qty.                          Description                            Torque
                                                                  Lb. In.   Lb. Ft.   N·m
  1      4     Clamp
  2      1     Hose (2-1/4 in.)
  3      1     Fitting
  4      2     Clamp
  5      1     Hose, Molded
  6      1     Hose (2-3/4 in.)
  7      1     Gasket
  8      4     Reed Plate Assembly
  9      1     Plate
  10     8     Screw (1/4-20 x 5/8 in.) With Dri Loc
  11     1     Gasket
  12     1     Adapter Assembly (Upper) Lower Adapter Not Shown
  13    14     Screw (1/4-20 x 7/8 in.)
  14     2     Screw (M6 x 30)
  15     2     Washer
  16     2     Bushing
  17     2     Grommet
  18     1     Bracket
  19     2     Screw (1/4-20 x 1-1/4 in.)
  20     1     Auto Enrichner
  21     4     Nut (3/8-16)
  22     4     Stud (3/8-16 x 1-5/8 in.) With Dri Loc
  23     2     Gasket
  24     1     Stud (1/4-20 x 1 in.) With Dri Loc
  25     1     Clamp




90-831996R1 JUNE 1996                               FUEL SYSTEM                             3B-13
Auto Enrichner                                                                                          o
                                                           a
System Description
                                                                                                    n
The Sport Jet utilizes an automatic enrichner to start
the engine. The auto enrichner is a self contained unit
                                                                                                    m
with three hose connections to allow for 1) fuel inlet,
2) air inlet, 3) fuel/air mixture outlet.
                                                                        b
Fuel is supplied to the auto enrichner by a hose con-                       c                   l
nection to the carburetor float bowl. Air is supplied to
                                                                            d
the valve by a hose connection to the sound attenua-
tor.                                                                     e
When the engine is cranked a fuel/air mixture is                          f
drawn into the engine from the auto enrichner by a
hose connection to the balance tubes. The carburetor               g                                                  k
shutters must be completely closed for the engine to
draw the fuel/air mixture from the auto enrichner.
                                                                        h
A wax pellet controls the position of a slide valve and
tapered needle. The stator supplies electrical current
to a heater element inside the auto enrichner. As the
heater element melts the wax pellet the fuel/air mix-               i
ture is slowly closed off by the slide valve/tapered                                        j
needle. The engine continues to run from the fuel/air
mixture supplied by the carburetor idle circuit.           a   -   Stator Leads (Yellow)   i - Fuel Inlet
                                                           b   -   Return Spring           j - Tapered Needle
                                                           c   -   Actuator Rod            k - Fuel/Air Mixture Outlet
                                                           d   -   Plastic Spring Guide        (Not All Outlets Are Used)
                                                           e   -   O-ring                  l - Compensating Spring
                                                           f   -   Slide Valve             m- Brass Guide
                                                           g   -   Air Inlet               n - Wax Pellet
                                                           h   -   Rubber Seat             o - Heater Element

                                                           Testing Auto Enrichner
                                                           On a cold engine the tapered needle will move from
                                                           full open to full closed after approximately 2 - 2.5 min-
                                                           utes of engine running.
                                                           On a cold engine resistance between the two yellow
                                                           leads is 18 - 20 ohms. As the engine warms up the re-
                                                           sistance reading will approach infinity.




3B-14                                              FUEL SYSTEM                             90-831996R1 JUNE 1996

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3b fuel system and carburation

  • 1. FUEL SYSTEM & CARBURETION 3 B FUEL PUMP RECIRCULATION SYSTEM REED VALVE ASSEMBLY AUTO ENRICHNER 90-831996R1 JUNE 1996 FUEL SYSTEM 3B-–1
  • 2. Table Of Contents Page Page Fuel Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-1 Inspecting and Installing General Information . . . . . . . . . . . . . . . . . . . 3B-1 Reed Block Assembly . . . . . . . . . . . . . . 3B-9 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-2 Reed Plate, Intake Manifold and Auto Enrichner - 90/95 HP . . . . . . . . 3B-10 Removing/Disassembling Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-2 Reed Plate, Adaptor Plate and Auto Enrichner - 120 HP . . . . . . . . . . . . . . 3B-12 Assembling and Installing Fuel Pump. . . . . . . 3B-3 Auto Enrichner . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-14 Fuel Pump Exploded View . . . . . . . . . . . . . . . . 3B-5 System Description . . . . . . . . . . . . . . . . . . 3B-14 Fuel Recirculation System . . . . . . . . . . . . . . . . . 3B-6 Testing Auto Enrichner . . . . . . . . . . . . . . . 3B-14 System Description . . . . . . . . . . . . . . . . . . . 3B-6 Testing Fuel Recirculation System . . . . . . 3B-6 Fuel Recirculation System 90/95 HP . . . . . . . . 3B-6 Fuel Recirculation System 1995 120 HP . . . . 3B-7 Fuel Recirculation System 1996 120 HP . . . . 3B-8 Reed Valve Assembly . . . . . . . . . . . . . . . . . . . . 3B-9 Removing and Inspecting Reed Valve Assembly . . . . . . . . . . . . . . 3B-9 3B-0 FUEL SYSTEM 90-831996R1 JUNE 1996
  • 3. Downward motion of the piston forces out the fuel DANGER pump diaphragm, closes the inlet check valve (to keep fuel from returning to fuel tank) and opens the FIRE AND EXPLOSION HAZARD. Observe fire outlet check valve, forcing fuel to the carburetors. prevention rules, particularly NO SMOKING. Before servicing any part of the fuel system, Checking for Restricted Fuel Flow disconnect electrical system at the battery. Drain Caused by Anti-Siphon Valves the fuel system completely. Use an approved container to collect and store fuel. Wipe up any While anti-siphon valves are helpful from a safety spillage immediately. Materials used to contain stand-point they clog, may be too small, or they may spillage must be disposed of in an approved have too heavy a spring. The pressure drop that oc- receptacle. Any fuel system service must be curs with these valves can create operational prob- performed in a well ventilated area. lems and/or powerhead damage by restricting flow of fuel. Some symptoms of restricted (lean) fuel flow are: FUEL LEAKAGE FROM ANY PART OF THE FUEL 1-Loss of fuel pump pressure SYSTEM CAN BE A FIRE AND EXPLOSION 2-Loss of power HAZARD WHICH CAN CAUSE SERIOUS BODILY 3-High speed surging INJURY OR DEATH. Careful periodic inspection of 4-Preignition/detonation (piston dome erosion) the entire fuel system is mandatory, particularly 5-Engine hesitates upon acceleration after engine storage. All fuel components, 6-Engine runs rough including fuel tanks, whether plastic, metal, or 7-Engine quits and cannot be restarted fiberglass, fuel lines, primer bulbs, fittings, 8-Engine will not start swelling, and must be inspected for corrosion. 9-Vapor lock Any sign of leakage or deterioration necessitates Any type of anti-siphon device must be located be- replacement before further engine operation. tween the engine fuel inlet and fuel tank outlet. A method of checking [if such a device (or bad fuel) is a problem source] is to operate the engine with a sep- Fuel Pumps arate fuel supply which is known to be good. General Information If it is found that the anti-siphon valve is the cause of the problem, either 1) replace the anti-siphon valve, Fuel Pump Description/Operation or 2) replace it with a solenoid-operated fuel shutoff The fuel pump is a crankcase-pressure-operated, di- valve. aphragm-type pump. Crankcase pulsating pressure Testing is transferred by way of a passage (hole) from the crankcase to the fuel pump. Install clear fuel hose(s) between fuel pump and car- buretor(s). Run engine, and inspect hose(s) for air When the piston travels upward a vacuum is created bubbles. If air bubbles are found, see “Air Bubbles in in the crankcase. This vacuum pulls in the fuel pump Fuel Line” . If air bubbles are NOT found, see “Lack diaphragm, the inlet check valve (in fuel pump) is of Fuel Pump Pressure”. opened fuel is drawn into fuel pump. 90-831996R1 JUNE 1996 FUEL SYSTEM 3B-1
  • 4. Troubleshooting Fuel Pump Removing/Disassembling Fuel Pump PROBLEM: Air Bubbles in Fuel Line 1. Loosen screw on sediment bowl. Possible Cause Corrective Action 2. Remove bowl from pump body. Low fuel in tank. Fill tank. Loose fuel line connec- Inspect and tighten con- tion. nections. Fuel pump fitting loose. Tighten fitting. A hole or cut in fuel line. Inspect condition of fuel lines and replace any found bad. Fuel pump anchor Inspect and tighten all screws loose. screws. Fuel pump gaskets Rebuild fuel pump. a worn out. PROBLEM: Lack of Fuel Pump Pressure a - Screw Possible Cause Corrective Action 3. Remove gasket and screen. Anti-siphon valve. Refer to “Checking for Restricted Fuel Flow Caused by Anti-siphon Valves” preceding. Air in fuel line. “Air Bubbles in Fuel Line” preceding. a Dirty or clogged fuel fil- Clean or replace filter. ter. Dirty or clogged fuel Clean or replace pickup. pickup in fuel tank. b Worn out fuel pump dia- Rebuild pump. phragm. Defective check valves Rebuild pump. a - Gasket in fuel pump. b - Screen Pulse hole plugged. Remove fuel pump and and clean out hole. Diaphragm gasket dis- Align or replace gasket torted or out of place. as necessary. Special Tools Description Part Number Hose Clamp Pliers FT-8900 RTV Sealant 92-90113--2 3B-2 FUEL SYSTEM 90-831996R1 JUNE 1996
  • 5. 4. Remove and disassemble fuel pump fitting, 6. Replace fuel pump check valves as necessary. screws and washer, nuts, fuel pump body, booster spring retainer, booster spring, diaphragm, gas- ket, spacer, and spacer plate gasket. c c b i j h a g d e b a - Center Check Valve c - Gasket b - Second Stage Check d - Screws Valve e - First Stage Check Valve e NOTE: Removal of the second stage check valve f may cause permanent damage to the pump body, therefore, if replacement is necessary it may be nec- d essary to replace the pump body. a 7. Replace bowl gasket, fuel pump body gasket, and center check valve gasket. a - Fuel Pump Fitting f - Booster Spring IMPORTANT: Replace all worn and/or damaged b - Screw and Washer g - Diaphragm parts. c - Nut h - Gasket d e - - Fuel Pump Body Booster Spring Retainer i j - - Spacer Spacer Plate Gasket Assembling and Installing 5. Test fuel check valves by lightly pressing on plastic Fuel Pump seats. 1. Install booster spring and retainer. S Be sure check valve seats when tension is re- leased. b a a - Spring b - Retainer 2. Position diaphragm and gasket on pump body. 90-831996R1 JUNE 1996 FUEL SYSTEM 3B-3
  • 6. 3. Compress spring using a putty knife. Install screws 6. Install fuel hoses. in pump body. b a c b a a a - Fuel Outlet Hose a - Long Screws b - Fuel Inlet Hose Connected to Sediment Bowl b - Short Screws c - Pulse Hose 4. Install spacer plate, nuts and gasket. 7. Install screen in sediment bowl. Install sediment bowl on fuel pump. a b a a - Screen - Edge Turned Toward Engine c 8. Install gasket on pump body. a - Spacer Plate b - Nuts c - Gasket 5. Position fuel pump assembly on transfer port cov- er. Tighten screws securely. S Apply sealant (p/n 92-90113--2) to threads of fit- ting. Install fitting. a a - Gasket, Aligned On Pump Body Keyway a a - Fitting 3B-4 FUEL SYSTEM 90-831996R1 JUNE 1996
  • 7. IMPORTANT: Position sediment bowl with hose fitting at the 4 o’clock position. a a - Hose Fitting At 4 O’Clock Position Fuel Pump Exploded View RTV Sealant 92-90113--2 90-831996R1 JUNE 1996 FUEL SYSTEM 3B-5
  • 8. Fuel Recirculation System Testing Fuel Recirculation System 1. Test for proper air flow through check valves as in- System Description dicated by arrows. At idle, unburned fuel collects and puddles in the crankcase behind the reed valves. The recirculation system is a means to route this excess, unburned fuel back to the combustion chamber. One way check valves are located on the crankcase cover, typically below the carburetors. Crankcase pressure forces the puddled fuel through the check valves. A hose connected to the check valve routes the fuel to the transfer port cover, whereby the fuel is introduced back to the combustion chamber. Fuel Recirculation System 90/95 HP 3B-6 FUEL SYSTEM 90-831996R1 JUNE 1996
  • 9. Fuel Recirculation System 1995 120 HP 90-831996R1 JUNE 1996 FUEL SYSTEM 3B-7
  • 10. Fuel Recirculation System 1996 & 1997 120 HP 3B-8 FUEL SYSTEM 90-831996R1 JUNE 1996
  • 11. Reed Valve Assembly Inspecting and Installing Reed Block Assembly Removing and Inspecting Reed Valve 1. Inspect reeds for any chipping or cracking. Assembly NOTE: The reeds are not serviceable, replace reed WARNING block assembly if any discrepancies are found. Always disconnect battery and remove spark 2. Inspect reed opening. Replace reed block assem- plug leads from spark plugs before working on bly if reed is standing open more than .010” (.254 motor. mm). 1. Remove attenuator cover. 2. Remove carburetors. SEE CARBURETOR SECTION FOR MORE INFOR- a MATION 3. Remove auto enrichner. b 4. Remove recirculation hose from manifold. c 5. Remove bolts securing manifold assembly to d crankcase cover. 6. Remove manifold assembly from cylinder block. 7. Remove reed block assembly from reed plate adaptor. a - Maximum Opening .010” (.254 mm) b - Reed Stop c - Reed d - Reed Block a 3. Clean all gasket surfaces. b 4. Using new gaskets, install reed block assembly to c reed plate adaptor. 5. Using new gasket, install manifold and reed plate d assembly into cylinder block. Secure assembly to cylinder block with screws. e 6. Install auto enrichner. 7. Install recirculation hose to manifold. NOTE: 90/95 HP Shown 8. Install carburetors. a - Reed Block Assembly d - Gasket b - Gasket e - Manifold SEE CARBURETOR SECTION FOR MORE IN- c - Reed Plate Adaptor FORMATION 9. Install attenuator cover. 90-831996R1 JUNE 1996 FUEL SYSTEM 3B-9
  • 12. Reed Plate, Intake Manifold and Auto Enrichner - 90/95 HP 1 2 4 3 5 6 7 8 9 13 14 15 10 16 17 11 12 18 19 19 26 13 20 13 23 25 24 13 21 13 22 3B-10 FUEL SYSTEM 90-831996R1 JUNE 1996
  • 13. Item Qty. Description Torque Lb. In. Lb. Ft. N·m 1 3 Reed Block Assembly 2 1 Gasket (Top) 3 2 Gasket (Center/Bottom) 4 1 Adapter, Reed Plate 5 1 Gasket, Intake Manifold 6 1 Manifold Assembly, Intake 7 8 Screw (1/4-20 x 1”) 8 6 Stud (5/16-18 x 1-1/4”) With Dri Loc 9 6 Nut (5/16-18) 10 1 Elbow 11 6 Screw (1/4-20 x 1-1/2”) 12 2 Fitting 13 6 Clamp 14 1 Hose, Molded (Top) Connect to Upper Manifold Elbow 15 1 Bracket 16 2 Grommet 17 2 Bushing 18 2 Screw (M6 x 30) 19 4 Washer 20 1 Hose (4-3/4”) Connect to Middle Carburetor 21 1 Auto Enrichner 22 1 Hose, Molded (Bottom) Connect to Lower Manifold Elbow 23 2 Fitting 24 1 Clamp 25 1 Stud (1/4-20 x 1-1/4”) With Dri Loc 26 4 Screw (1/4-20 x 1-1/4”) 90-831996R1 JUNE 1996 FUEL SYSTEM 3B-11
  • 14. Reed Plate, Adaptor Plate and Auto Enrichner - 120 HP 1 2 7 8 3 1 4 4 1 6 5 1 9 13 25 24 23 10 11 22 12 21 13 20 17 16 15 14 19 15 18 3B-12 FUEL SYSTEM 90-831996R1 JUNE 1996
  • 15. Item Qty. Description Torque Lb. In. Lb. Ft. N·m 1 4 Clamp 2 1 Hose (2-1/4 in.) 3 1 Fitting 4 2 Clamp 5 1 Hose, Molded 6 1 Hose (2-3/4 in.) 7 1 Gasket 8 4 Reed Plate Assembly 9 1 Plate 10 8 Screw (1/4-20 x 5/8 in.) With Dri Loc 11 1 Gasket 12 1 Adapter Assembly (Upper) Lower Adapter Not Shown 13 14 Screw (1/4-20 x 7/8 in.) 14 2 Screw (M6 x 30) 15 2 Washer 16 2 Bushing 17 2 Grommet 18 1 Bracket 19 2 Screw (1/4-20 x 1-1/4 in.) 20 1 Auto Enrichner 21 4 Nut (3/8-16) 22 4 Stud (3/8-16 x 1-5/8 in.) With Dri Loc 23 2 Gasket 24 1 Stud (1/4-20 x 1 in.) With Dri Loc 25 1 Clamp 90-831996R1 JUNE 1996 FUEL SYSTEM 3B-13
  • 16. Auto Enrichner o a System Description n The Sport Jet utilizes an automatic enrichner to start the engine. The auto enrichner is a self contained unit m with three hose connections to allow for 1) fuel inlet, 2) air inlet, 3) fuel/air mixture outlet. b Fuel is supplied to the auto enrichner by a hose con- c l nection to the carburetor float bowl. Air is supplied to d the valve by a hose connection to the sound attenua- tor. e When the engine is cranked a fuel/air mixture is f drawn into the engine from the auto enrichner by a hose connection to the balance tubes. The carburetor g k shutters must be completely closed for the engine to draw the fuel/air mixture from the auto enrichner. h A wax pellet controls the position of a slide valve and tapered needle. The stator supplies electrical current to a heater element inside the auto enrichner. As the heater element melts the wax pellet the fuel/air mix- i ture is slowly closed off by the slide valve/tapered j needle. The engine continues to run from the fuel/air mixture supplied by the carburetor idle circuit. a - Stator Leads (Yellow) i - Fuel Inlet b - Return Spring j - Tapered Needle c - Actuator Rod k - Fuel/Air Mixture Outlet d - Plastic Spring Guide (Not All Outlets Are Used) e - O-ring l - Compensating Spring f - Slide Valve m- Brass Guide g - Air Inlet n - Wax Pellet h - Rubber Seat o - Heater Element Testing Auto Enrichner On a cold engine the tapered needle will move from full open to full closed after approximately 2 - 2.5 min- utes of engine running. On a cold engine resistance between the two yellow leads is 18 - 20 ohms. As the engine warms up the re- sistance reading will approach infinity. 3B-14 FUEL SYSTEM 90-831996R1 JUNE 1996