MARK-3 ®

Portable 4-Stage Fire Pump

Instruction & Service Manual
 2 MARK-3® Service Manual www.wildfire-env.com • 1-800-426-5207

Pump Clamp

Throttle Muffler

Digital Overspeed Switch

(DOS)

Spark Arrestor

Choke Lever

Priming Inlet
Air Filter

Electronic Ignition Module

Fuel Supply Hose Connect Discharge Outlet Suction Inlet

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TABLE OF General Information Page Major Overhaul Service Page

CONTENTS SPECIFICATIONS 4 ENGINE OVERHAUL SERVICE PROCEDURE 37
SERIAL NUMBERS 5 DISASSEMBLY PROCEDURE FOR ENGINE 38
REASSEMBLY SERVICE FOR ENGINE 39-40
Engine Operating DISASSEMBLY PROCEDURE FOR PUMP END 41
STARTER 6 ASSEMBLY PROCEDURE FOR PUMP END 42-43
OPERATING INSTRUCTIONS 6-7
THE IMPORTANCE OF PROPER Miscellaneous
FUEL MIXTURE 8-11 FRAME 44
FLOODING 12 QUICK-CONNECT FUEL LINE 44
COLD WEATHER 12 NOISE REDUCTION MUFFLER 45
TROUBLESHOOTING CHART 13 DECARBONISING 45
ELECTRONIC IGNITION 14

Technical Specifications
Pump Unit TORQUE VALUES 46
PUMP OPERATION AND LUBRICATION 14 CYLINDER SPECIFICATIONS 46
PUMP TEST KIT 16 CLEARANCE DATA AND LIMITS 46
PUMP ADJUSTMENTS 16 SOLID STREAM NOZZLES 46
DIGITAL OVERSPEED SWITCH (DOS) 17 MAXIMUM PERFORMANCE VALUES 46
METER HEAD OF WATER AND 46
Regular Maintenance EQUIVALENT PRESSURE
MAINTENANCE CHECK LIST 19
SERVICING SPARK PLUG 20 Appendices
UPGRADED SPARK PLUG CAP 20 ELECTRONIC IGNITION, CONVERSION
INSTRUCTIONS (POINT TO CDI) 47-52
ELECTRONIC IGNITION UNIT 21
ELECTRONIC IGNITION, INSTALLATION
ELECTRONIC IGNITION MODULE SETTINGS 22
INSTRUCTIONS 53
DECOMPRESSION SWITCH R-233DS 23
MECHANICAL CUT-OUT SWITCH 54
SERVICING CARBURETOR 24-26
STOP SWITCH KIT 55
CARBURETOR TROUBLESHOOTING CHART 27
DOS INSTALLATION INSTRUCTIONS 55-59
AIR FILTER & CYLINDER ASSEMBLY 28
IGNITION TIMING TOOL 60
COOLING SYSTEM 29
THE REWIND STARTER 30-34 Parts Index 61-64
MAGNETO 35-36
Warranty 67
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GENERAL SPECIFICATIONS
INFORMATION The MARK-3 pump end (12-16 / 12-16S) is an anodized horizontal 4-stage centrifugal precision built
pump. Both the 2” (51 mm) NPSH* male suction connection and 1 1/2” (38 mm) NPSH male
discharge connection are made to standard forestry thread specifications.
The MARK-3 engine is a one-cylinder, two-cycle, air-cooled engine incorporating ball and roller
bearings. The unit is also equipped with a rewind pull-cord starter and automatic cutout switch.
This handbook *NPSH stands for straight pipe threads also abbreviated by IPT or SIPT.
includes
specifications, WARNING
performance data, • The improper use of this pump could result in serious injuries.
operating instructions, Please read the manual before using your MARK-3 pump unit.
normal servicing
• Always wear eye and ear protection when operating the pump unit.
information and parts
list for the MARK-3
centrifugal fire pump DANGER DANGER
unit.The MARK-3 unit
has been designed
to meet all the
requirements of
• Be careful, never touch the muffler, as it can reach very high temperatures and cause serious burns.
advanced techniques
Always allow enough time after stopping the unit for the muffler and surrounding parts to cool down.
in forest fire control,
• Always use proper fuel mixture to ensure suitable lubrication.
including USDA Forest
Service Specifications CHARACTERISTICS
No. 5100-274C. This
Complete unit 59.8 lbs 27.1 kg
versatile unit enables
the pump to be used Height 16 ¼” 41 cm
for high pressure Width 12” 31 cm
and volume (B-2 Length 23” 58 cm
volume Pump End Pump end only 15 lbs 6.8 kg
interchangeability). Max. engine power 10 HP 7.46 kW
It is also suitable for Carburetor Tillotson all position diaphragm type with integral fuel pump and filter
rural and municipal Ignition system Ducati Electronic Ignition
fire protection, or Spark plug* Bosch M4AC, NGK A8
wherever a large Fuel consumption 4.5 L/hr (1.2 US gal/hr)
volume of water or
high pressure is * For MARK-3 engines that use 14 mm spark plugs we recommend:
Bosch W4AC, NGK B8HS, Champion L82C
required. Tandem
operations enable to MAXIMUM PERFORMANCE
move water over
Pressure Discharge Flow
greater distances or
higher altitudes. psi kPa bar US GPM IMP GPM L/min
0 0 0 98 82 371
50 345 3.45 89 74 337
75 517 5.17 83 69 314
100 690 6.90 78 65 295
150 1034 10.34 65 54 246
200 1379 13.79 52 43 197
250 1724 17.24 38 32 144
300 2069 20.69 25 21 95
350 2413 24.13 9 7 34
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380 2620 26.20 0 0 0

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2758
GENERAL

400
MK-3
MK-3 Maximum Pressure: 380 PSI
INFORMATION (2620 kPa)

2068
300
Free flow: 98 US gals/min
(370 L /min)
Maximum Head: 878' (268 m)

1379
200
MK-3-B2 MK-3-B2
Maximum Pressure: 155 PSI
(1068 kPa)

100
689
Free flow: 180 US gals/min
(681 L /min)
Maximum Head: 358' (109 m)

kPa
PSI
US gals/min 50 100 150 200
L /min 189 379 568 758

READ ME FIRST
24:1 Good lubricating is important. Use a high quality
API-TC certified 2-cycle oil in preparing the gas/oil
mixture (24:1). Always allow the engine to warm-up
for at least 2 minutes before using full throttle. DO
NOT run engine with pump disconnected or dry pump.

1.1

1.2

SERIAL NUMBERS
Pump end serial number is located on the side of the pump (1.1).
Engine serial number is stamped on a nameplate attached to the crankcase (1.2).
These serial numbers are the key to various design details pertaining to the original manufacture
of each unit. Therefore, it is very important to specify serial numbers whenever ordering
parts and tools or when requesting information.

1.3 DIRECTIONAL REFERENCES

All references to right side and left side of unit are made as they appear to operator when facing
rewind starter, thus the carburetor is on the right side and the muffler is on the left side.
Viewed in this manner (facing the recoil starter), the engine will rotate in a clockwise direction (1.3).
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ENGINE FOR TROUBLE FREE OPERATION

OPERATING • DO NOT run engine at full speed until thoroughly warmed up.
• DO NOT lift strainer out of the water while pump is operating.
• DO NOT run engine with pump disconnected.
• DO NOT run pump when dry.
• Check strainer frequently to make sure that it is not clogged with moss, leaves, etc.
TIP
• DO NOT use suction hose without footvalve strainer.
If the rewind starter should • Remove and drain pump after final use.
break while the unit is on
the fire line, the complete STARTER
rewind starter assembly can The starter is an automatic rewind type. A proper operating technique will add many hours of life to
be easily removed, thereby the starter rope and starter.
gaining access to a manual Grasp handle firmly and pull slowly until resistance (past compression), then continue to pull with a
starter pulley which is short, vigorous stroke. Pulling handle sideways causes excessive wear. If kickback occurs, let go of
mounted on the flywheel. handle immediately.
Using a rope, wrap around
starter pulley and pull. When engine starts, retain grip on handle and allow rope to rewind slowly.
Make sure rope wrapping Note: The rope should be replaced when wear is apparent.
will ensure clockwise See rewind starter Servicing and Parts (page 31).
rotation (from starter view).
OPERATING INSTRUCTIONS
Oil: API-TC certified 2-cycle mixing oil.
CAUTION Gas: Unleaded 87 octane.
Not enough emphasis can
Mixing ratio: 24:1. Mix 24 parts of gasoline with 1 part of two-cycle oil.
be placed on the use of (Do not use gasoline that has a concentration of ethanol that is higher than 10%).
correct gasoline and oil Do not use poor quality oil, high detergent oil or oil with solid additives (graphite, moly, T.F.E., etc.).
mixture. Using less than the Too much emphasis cannot be placed on the use of correct gasoline and oil mixture.
recommended portion of oil
will cause overheating and
possible engine damage. MIXTURE RATIO
Using more than the
recommended proportion of Oil Gasoline
oil will cause spark plug 1 L (0.22 IMP gal, 0.26 US gal) 24 L (5.3 IMP gal, 6.3 US gal)
fouling, erratic carburetion, 1 US Quart (0.95 L) 6 US gals (5 IMP gal, 22.75 L)
excessive exhaust smoke
and rapid carbon deposits.

CONTROLS
1
2 There are only 3 controls which are used for normal operation: (1.4)
1 DOS (Digital Overspeed Switch)

2 Throttle lever
3 3 Choke lever
24:1
1.4
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ENGINE TO START MARK-3 UNIT

OPERATING 1. Fill fuel supply tank with recommended fuel mixture.
2. Connect fuel supply line to fuel supply tank (1.5).
3. Attach fuel supply line to the adaptor located on right side of engine frame. Pump fuel to fill
supply line (1.6).
DO NOT use suction hose without footvalve strainer. DO NOT allow footvalve strainer to
rest on bottom of lake or riverbed.
4. Connect footvalve strainer to male end of suction hose, then fill suction hose with water and
connect to pump. 1 Use universal hose coupling wrench to tighten coupling firmly (1.8).
5. Connect discharge hose 2 , nozzles, etc., to pump. Use a rope or other means to keep strainer
at proper height, approximately 30 cm (1 foot) below water surface. If strainer is too close to
the water surface, it will draw air and pump may lose prime.
6. Fill pump with water manually or using a hand primer (B-5980), then reinstall priming cap and
1.5
tighten firmly (1.8).
7. Move throttle lever to "Start" and "Warm up" position (approx. 3 increments).
8. Close choke, if engine is cold.
9. Slowly turn engine until resistance (past compression).
10. Give starter rope several quick, steady pulls until engine “coughs”.
11. Open choke slightly and pull starter rope until engine runs.
12. Slowly open choke and allow engine to warm up for at least 2 minutes before using full throttle.
The MARK-3 engine was initially run-in at the factory. Full throttle operation can be used
1.6 provided the engine is given a thorough warm-up period beforehand.
Important: Failure to allow the engine to warm up may lead to piston scoring and possibly
more serious damage.

DIGITAL OVERSPEEED SWITCH (DOS)

The MARK-3 unit is equipped with a digital overspeed switch. This safety device will stop the
engine instantly and thereby eliminate overspeeding.
When the DOS automatically stops the engine, this is a warning that there is a problem. Do not
restart the engine until cause of trouble has been identified and corrected.

1.7
TO STOP MARK-3 UNIT
1. Move throttle lever to "Stop" position.
2. Allow unit to run for approximately 1 minute with throttle in this position.
B-5980
3. Press and hold "OFF" button on the DOS until the engine shuts down.
4. Remove and drain pump after final use.

2
1.8
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ENGINE THE IMPORTANCE OF FUEL / MIXTURE RATIO, AIR / FUEL

RATIO AND OIL CONSIDERATIONS
OPERATING
FUEL MIXTURE RATIO e.g.:
The ratio amount of gasoline to
2 cycle mixing oil can be classified
as either Rich or Lean.
20:1 30:1 40:1 etc.

RICH MIXTURE RATIO e.g.:

This is when the ratio of gasoline
to oil is less. 20:1 is richer than 24:1

CONS
Increased carbonizing of engine: Fuel does not burn efficiently:
• Deposits on exhaust port, • Reduced performance
piston and head • More pollution
• Excessive carbon build-up can cause Blockage of spark arrestor
scoring of piston and cylinder
• Excessive carbon build-up can
decrease heat dissipation
PROS
Need to de-carbonize more often
Good lubrication
Spark plug fouling
Able to operate at higher ambient temperatures

LEAN MIXTURE RATIO e.g.:

This is when the ratio of gasoline
to oil is higher. 30:1 is leaner than 24:1

CONS PROS
Decreased lubrication: Reduced carbonizing
• Possibility of piston / cylinder Fuel burns more efficiently:
scoring / seizure
• Clean burn
• Engine operates hotter
• Less pollution
More susceptible to damage
• Better performance
when operating at higher ambient
temperatures • Better fuel combustion
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ENGINE THE IMPORTANCE OF FUEL / MIXTURE RATIO, AIR / FUEL

RATIO AND OIL CONSIDERATIONS
OPERATING

PROPER MIXTURE
Wildfire recommends a mixture • Good lubrication
ratio of 24:1 using Castrol 2-Stroke • Good performance
Super Stroke (or similar) for the MK-3.
• Cost effective
• Reduced chance of scoring of piston / cylinder
• Possible to operate at high engine speed
& temperature without damage

24:1 • Reduced carbonizing

• Pump end does not get dirty
from excessive oil
• Engine operates at normal temperatures

THE IMPORTANCE OF PROPER AIR FUEL A/F RATIO

When adjusting the idle and high speed A/F RATIO

carburetor adjustment it is important not
to adjust the carburetor too lean or too The ratio of the amount of AIR to the amount
rich otherwise engine damage can result. of FUEL being introduced into the combustion
chamber

LEAN A/F RATIO RICH A/F RATIO

• The ratio of air to fuel is higher • The ratio of air to fuel is lower
(higher air content in the air / fuel ratio) (lower air content in the air / fuel ratio)
• Less fuel (gasoline + oil) in the air / fuel • More fuel (gasoline + oil)…more lubrication
mixture… less lubrication
• Engine runs cooler
• Less lubrication…possible piston /
• Carbonizes easier / quicker
cylinder scoring
• Performance decreased
• Not good to operate in high ambient
temperatures • Not as responsive
• Runs hotter • More smoking
• Burns cleaner • Combustion not as efficient
• Good performance (if too lean then
performance drops off)
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ENGINE A/F ADJUSTMENT: ALTITUDE VARIATIONS

OPERATING It is very important to adjust carburetor when moved from a HIGHER ALTITUDE to a LOWER ALTITUDE
and vice versa.
Example:
At higher altitudes there is less oxygen therefore you need to adjust the carburetor to maintain
a proper A/F RATIO (we need to decrease the amount of fuel in the A/F ratio…lean out). If the
carburetors (adjusted lean for high altitude) are not re-adjusted when the engine is taken down to
sea level conditions (lower altitude) the engine will be operating with a much leaner A/ F RATIO (more
air at lower altitudes) and possibly cause engine damage.

A/F ADJUSTMENTS: AIR FILTERS

The condition of the air filter can cause the A/F ratio to vary. A dirty air filter restricts the amount of
air that can enter the carburetor resulting in a richer A/F ratio. Some operators make the mistake of
adjusting the A/F ratio as the air filters gets dirtier by leaning out the carburetor instead of
cleaning/changing the air filter. As soon as the air filter is either changed or cleaned (A/F ratio not
re-adjusted) more air will be able to enter the carburetor resulting in a much leaner A/F mixture which
can result in possible engine damage.

A/F ADJUSTMENTS: DIFFERENT FUEL MIXTURE RATIOS

The A/F ratio and the fuel mixture ratio are closely linked. The following cases will better describe
how they are related.

LEAN FUEL MIXTURE RATIO

LEAN A/F RATIO RICH A/F RATIO
The A/F ratio is extremely critical when using a If the A/F ratio on the carburetor is adjusted rich,
lean Fuel Mixture Ratio. If the carburetor is the engine will begin to smoke due to improper /
adjusted too lean, then there will be less fuel incomplete combustion. A noticeable lack of
(gasoline + oil) which in turn results in decreased power will be observed.
lubrication. At this point the engine will be
operating hotter and if the ambient temperatures
are higher and if the engine is operating at a
higher engine speed, the possibility of engine
damage resulting is quite high. If the A/F ratio is
too lean, in addition to higher temperatures, a
loss of power will also be observed.

RICH FUEL MIXTURE RATIO

LEAN A/F RATIO RICH A/F RATIO
If the carburetor is adjusted with a lean A/F ratio, When dealing with a rich fuel mixture it is critical
there will be less fuel (gasoline + oil) which in not to operate the engine with a rich A/F ratio. If
turn will result in a decreased lubrication. With a this happens the engine will smoke and carbon
richer fuel mixture ratio, a lean A/F ratio setting deposits will form. It will be necessary to
is not as critical as with a Lean Fuel Mixture ratio. de-carbonize the carbon deposited areas. If the
There may still be enough lubrication (depending deposit formations are not removed, the engine can
on the fuel mixture ratio and the A/F ratio) to start to heat up and possible scoring could result
prevent engine damage but caution must be due to bits of the carbon breaking off and getting
taken to properly adjust the carburetors. lodged in between the cylinder and piston.
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A noticeable power loss will be experienced.

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ENGINE OIL CONSIDERATIONS

OPERATING There are different types of 2 cycle oils that SYNTHETIC
can be used:
• Mixes very well with oil since composition
• Mineral of Synthetic oil is close to that of gasoline
• Castor Bean Oil • Produces low ash therefore reduced deposit
formation
• Synthetic
• Leaves a thin lubricating film on cylinder
• Semi-synthetic
wall
MINERAL
• Thin lubricating film on cylinder wall has
• Cost effective, not too expensive difficulty providing adequate lubrication
• Readily available when dealing with a hot air cooled engine

• Leaves a nice lubricating film on the cylinder • Much more expensive

walls and does not run off • Not readily available
• Good lubricity • Possible varnishing on cylinder walls
• Lubricating film on cylinder wall does not • Some manufacturers may require a break-in
run off when in storage over periods of time period or greening of the engine
• Higher ash • Cannot readily interchange from synthetic
• Can leave deposit formation on: to non-synthetic and back (dependant on
- exhaust port manufacturers recommendations)
- piston rings • The thin lubricating film on cylinder walls
- piston crown can run off during longer storage periods
leaving the surface unprotected; corrosion
and dry starts leading to damage
CASTOR BEAN OIL • Dyno test have not shown an increase in
• Very gummy dirty oil performance using synthetic oil
• Resists seizure under extreme conditions
• Very high ash… much higher deposit SEMI-SYNTHETIC
formation
• A compromise between synthetic and
• Requires frequent disassembly for deposit mineral based oils
removal
• Higher cost
• Used in racing where crucial lubrication
is required and frequent disassembly, • Not always readily available
cleaning and re-assembly is performed • Has a lesser degree of run off

CONCLUSION
Wildfire suggests using Castrol 2 Stroke Super Stroke or similar
mixing oil due to the positive results when used in the MK-3 at a
24:1 mixture ratio. Tests have been conducted using synthetic and
semi-synthetic oils but found varying results with variations in
fuel quality and oil quality with some results leading to piston
damage or piston ring sticking.
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ENGINE FLOODING
Flooding refers to an accumulation of excess fuel in cylinder, mainly due to excessive use of choke.
OPERATING
When the engine is in a flooded condition, an over-rich fuel-air mixture is induced into the cylinder.
This mixture does not ignite readily and usually fouls the spark plug.

CLEARING A FLOODED ENGINE

Remove fuel supply line from engine or close fuel supply valve (if equipped). Remove spark plug. With
both choke and throttle in fully open position, pull starter rope several times until excess fuel is
COLD OPERATION exhausted. Before reinstalling spark plug, clean and dry electrode and insulator tip.

In cold operation, it is
good practice to put a COLD WEATHER
small quantity of Recommended Procedure for Cold Weather or Prolonged Storage
aluminum compatible
antifreeze into the pump The following procedure is recommended to ensure proper protection of the engine if the engine is
end through the priming to be left idle for prolonged periods between uses or if there is a possibility that the engine may be
cap immediately after stored in an unheated area where freezing temperatures may occur.
use to prevent damage
1. With pump unit running at low RPM, remove the quick-connect fuel line from the quick-connect
from freezing.
fitting on the engine.

2. Allow engine to run until all fuel has left the carburetor and the engine stops.

3. Remove spark plug.

4. Rotate crankshaft until piston is at top dead centre.

5. Pour 30 ml (1 oz) of oil into spark plug opening (use same oil grade used in fuel mixture).

6. Rotate crankshaft 2 or 3 times to ensure that cylinder walls are well coated with oil, then bring
piston to top dead centre.

7. Reinstall spark plug.

8. Keep the pump unit in dry storage above freezing temperature.

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TROUBLESHOOTING CHART
ENGINE DOES NOT START OR STARTS
MOMENTARILY THEN STOPS ENGINE DOES NOT IDLE PROPERLY

Possible cause Remedy Possible cause Remedy

Fuel supply tank empty Refill fuel tank Carburetor mountings loose Tighten mountings
Fuel supply valve closed Open supply valve Too much oil in fuel mixture See “Engine Lubrication and Fuel“
Air vent on fuel tank closed Open air vent or unscrew cap Idle mixture screw misadjusted See “Carburetor Adjustment”
Defective fuel supply hose Replace Spark plug fouled or defective Clean or replace
Dirty fuel strainer screen Clean or replace Wrong type of spark plug Use plug recommended
Leak in fuel supply system Tighten or replace fittings Main adjustment screw See “Carburetor Adjustment”
Carburetor mountings loose Tighten mountings misadjusted
Water or dirt in fuel system Drain; flush thoroughly Improper timing Refer to “Electronic Ignition Unit“
Engine flooded See “Flooding”
Too much oil in fuel mixture See “Operating Instructions”
Spark plug fouled or defective Clean or replace ENGINE DOES NOT DEVELOP NORMAL
No spark See “Electronic Ignition POWER AND/OR OVERHEATS
Module Settings” Possible cause Remedy
Carburetor mountings loose Tighten mountings
Wrong gasoline in fuel mixture See “Engine Lubrication and Fuel“
ENGINE RUNS IRREGULARLY OR MISSES Wrong oil in fuel mixture See “Engine Lubrication and Fuel“
Possible cause Remedy Not enough oil in fuel mixture See “Engine Lubrication and Fuel“
Defective fuel supply hose Replace Too much oil in fuel mixture See “Engine Lubrication and Fuel“
Dirty fuel strainer screen Clean and replace Air filter dirty Replace
Leak in fuel supply system Tighten or replace fittings Spark plug fouled or defective Clean or replace
Carburetor mountings loose Tighten mountings Wrong type of spark plug Use plug recommended
Water or dirt in fuel system Drain; flush thoroughly Cooling system dirty Clean cooling system
Wrong gasoline in fuel mixture See “Engine Lubrication and Fuel” Muffler blocked or dirty Replace
Too much oil in fuel mixture See “Engine Lubrication and Fuel” Main adjustment screw See “Carburetor Adjustment”
misadjusted
Air filter dirty Clean or replace
Improper timing Refer to “Electronic Ignition Unit“
Idle mixture screw misadjusted See “Carburetor Adjustment”
Spark plug fouled or defective Clean or replace
Wrong type of spark plug Use recommended plug
ENGINE SOUNDS LIKE A FOUR STROKE
Improper timing Refer to “Electronic Ignition Unit”
Possible cause Remedy
Too much oil in fuel mixture See “Engine Lubrication and Fuel”
ENGINE BACKFIRES Engine not warmed up properly Allow longer warm up period
Possible cause Remedy Main adjustment screw See “Carburetor Adjustment”
misadjusted
Spark plug fouled or defective Clean or replace
Air filter dirty Clean or replace
Defective carburetor Replace
Improper timing Refer to “Electronic Ignition Unit”
Improper timing Refer to “Electronic Ignition Unit”

Refer also to the “Servicing Carburetor” section for additional

Trouble Data and Service Information.
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ENGINE ELECTRONIC IGNITION

OPERATING In May of 2004, Wildfire announced that the standard MARK-3 units would feature an
electronic ignition system as opposed to the previous pointed ignition system.
The upgrade to the electronic ignition system has eliminated the need for regular maintenance
associated with breaker points. The electronic ignition system uses a magnetic pickup located on
the flywheel which, when passing over a certain point on the stator, will induce a high
voltage that causes the spark plug to fire at the proper moment.
The electronic ignition module is equipped with spark advance, thus allowing for a cleaner burn
at higher RPM levels. The engine will run smoother and will be more responsive. Note that when
the engine is started cold, it will run "rough" (as if the timing is off) for about 15-30
seconds, after which the engine will run smoothly.
In order to convert a MARK-3 from breaker points to the upgraded electronic ignition system, a
retrofit kit was created (B-7595). This manual provides step-by-step instructions on how to perform
the conversion.
The breakdown of the electronic ignition is shown below. The electronic module is placed in an
A more efficient and aluminium box located on the frame below the carburetor shroud.
maintenance free electronic
ignition system.

Ref. # Part# Description Qty

-- B-7595 MARK-3 Conversion Kit (Point to CDI)
1 R-271 Electronic ignition conversion kit 1
2 A-7589 Mounting block, electronic ignition 1
3 D-2902-9 Grommet 2
4 FAST-18 Bolt, hex, steel, plated 2
5 QHOSNEO5/16BL* Hose, 5/16" ID x 7/16" OD, neoprene 0.5
6 QWICO18GABLK* Wire, 18 ga., black 0.83
7 PART-37 Female disconnect terminal, insulated 1
8 FAST-20 Bolt, hex steel plated 2
9 FAST-510 Flat washer, steel plated 2
10 R-150 Lock nut, steel, plated 5
11 A-6510 Decal for electronic ignition box 1
12 B-5562-18 Plastic coated clamp 1
The electronic ignition allows 13 C-7010-12C Female bullet terminal, insulated 1
for a smoother and more -- MAN-B-7595 Manual, MARK-3 conv. kit, point to CDI 1
responsive engine run. -- PART-260* Split loom, 3/8" 0.92
-- QHEATSH1/2D* Heat shrink tubing, 1/2" 0.17
-- QHEATSH1/4D* Heat shrink tubing, 1/4" 0.17
* Please note that these items are not sold as spare parts.
NOTE
6
For step-by-step instructions 1 1 2 3
5
to convert from a pointed 7
engine to CDI please refer 4
to the Appendix.

13 12 11 1

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PUMP UNIT PUMP OPERATION AND LUBRICATION

Ref. # Part # Description Qty

_
212-170P Pump clamp
1 A-4460 Lever sub-assembly 1
2 A-4452 Side link for lever 1
3 C-4462-5 Cotter pin 3
4 A-4455 Clevis pin, lever side 2
5 B-4461 Clamp, top half 1
6 B-4457 Clamp, bottom half 1
7 A-4454 Clevis pin, eye bolt side 1
8 A-4456 Knob for tension adjustment 1
9 A-4453 Eye bolt 1

1 2

8 9
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PUMP UNIT PUMP LUBRICATION

Pumps requiring greasing must be lubricated every 8 hours of operation and after each use.
Use a clean grease gun filled with fresh grease. Remove dirt from grease fitting before applying grease
gun. Grease should be pumped slowly into grease zerk while rotating the pump shaft. Continue
IMPORTANT pumping until fresh grease appears around bearing ring. Wipe off excess grease.

Pump ends (12-16S) with Do not use graphite grease or a pressurized grease gun.
the sealed bearing (12-48S)
do not require greasing. TO REMOVE PUMP FROM ENGINE

1. Lift pump clamp lever.

2. Release tension adjusting knob at bottom of clamp.
3. Remove clamp by tapping bottom end of each half clamp.
4. Remove pump from engine.

TO ATTACH PUMP TO ENGINE

IMPORTANT
1. Place flexible buffer coupling on engine coupling pins.
Apply FINGER PRESSURE 2. Align flexible buffer coupling holes to pump end coupling pins and install.
ONLY to close pump clamp
lever. Excessive pressure 3. Attach pump clamp. Carefully align clamp positioning pins with flange stub.
will damage or break 4. Adjust tension knob located at bottom of clamp to obtain a light pressure on
clamp link.
clamp ring.

TO DRAIN PUMP
It is recommended that the pump be drained after usage. This is a MUST during cold weather, to
prevent damage to pump, due to freezing.
1. Remove discharge hose, suction hose, and priming cap.
2. Drain pump by tilting pump body several times.
3. Stand pump on suction nozzle end for several minutes to complete drainage.
4. Replace discharge, suction, and priming caps.

TESTING PROCEDURE

The A-2388 pump test kit is designed to verify the condition of a pump unit by completing a
performance test. This is achieved through running the unit at three key nozzle bore sizes: ¼” (6 mm),
⅜” (9.5 mm), and at ½” (12.7 mm). Verify that the pressure output at full throttle is at or above the
below-listed minimal pressure ranges by reading the pressure gauge at each nozzle setting. The pump
unit should be sent to a service center if it fails any one of the testing points. (See next page for kit
breakdown).

Nozzle *1/2" 7/16" *3/8" 5/16" *1/4" 1/8"

Size 12.7 mm 11 mm 9.5 mm 8 mm 6 mm 3 mm
Minimal 100-105 psi 125-130 psi 165-170 psi 210-215 psi 255-260 psi 315-320 psi
Pressure 689-724 kPa 862-896 kPa 1138-1172 kPa 1448-1482 kPa 1758-1793 kPa 2172-2206 kPa
Range

*Test kit includes ¼” (6 mm), ⅜” (9.5 mm), and at ½” (12.7 mm) test points
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PUMP TEST KIT Ref. # Part # Description Qty

-- A-2388 Pump test kit (incl. all the parts listed below)
1 A-2392 Pressure gauge 0-400 psi (0-2800 kPa) 1
2 F5095E Hose SPEC 187-1 1/2" x 10' with aluminum coupling
NPSH M/F F5095E00F10RAAFSS 1
3 A-2389 Pump test kit box 1
4 A-2391 Rubber hose assembly (incl. a set of 2 adaptors A-2391B) 1
5 A-2391B Adaptor Female NPT-Swivel Female 2 2
6 A-2390A Shut-off valve 1
7 A-2390 Pressure gauge adaptor 1 1/2" (38 mm) female NPSH to
1 1/2" (38 mm) male NPSH 1
8 A-2395 Brass calibrated nozzle tip set:
includes 1/4” (6 mm), 3/8” (9.5 mm) 1
9 C-1933 Calibrated nozzle, 1/2" (12.7 mm) 1

PUMP ADJUSTMENTS
Overspeeding may occur if:
1. Pump not primed properly.
• Suction hose and/or pump body not completely filled with water.
IMPORTANT
• A bend in the suction hose, located higher than the pump suction inlet, causing an air lock.
Carburetor should be (The suction hose between the pump and water supply must have a downward slope.)
properly adjusted before
2. Loose suction hose coupling or priming cap.
starting performance test. See
"Carburetor Troubleshooting 3. Footvalve strainer clogged or too close to surface of water.
Chart". In addition, the pump
4. Pump loses prime.
unit should be set up as close
as possible to water source. • Due to lack of water, air lock may form in the suction hose when pump unit works against a
high delivery head. If this happens, disconnect the discharge hose from the pump then reprime
pump in the normal manner.
• Pump runs out of water, either because of lack of sufficient water supply or by attempting to
pump water from a shallow water source.
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PUMP UNIT The footvalve must remain at least 30 cm (1 foot) under the water surface while pump is operating.
All suction couplings, including footvalve, must be wrench tightened. Proper fitting gaskets must be
used in all coupled joints. Worn or dried out gaskets should be replaced with new gaskets.

DIGITAL OVERSPEED SWITCH (DOS)

NOTE One common failure associated with fire pumps is in overspeed condition. This occurs when the pump
For information on previous end experiences a loss of prime. Not enough water in the pump end severely unloads the engine and
mechanical cut-out switch causes it to race to speeds outside safe operating parameters.
system (B-6288) please
Wildfire previously used a mechanical cut-out switch to deal with the problem of overspeed.
refer to the Appendix
section. The Digital Overspeed Switch (DOS) continuously monitors the engine’s speed through the use of a
microcontroller which, once overspeed is detected, re-validates that the condition exists then
immediately shuts down the pump. Adjustment of a tension spring is no longer required. An “ON/OFF”
switch is also no longer required. This also reduces the amount of wiring and spare parts necessary
for each unit. Can be installed on any MARK-3 equipped with electronic ignition module.
DOS
POWER
OFF button
The DOS unit derives power from the engine and therefore does not require the use of batteries. The
unit powers up once the engine is operating.

INTEGRATED OFF SWITCH

With the DOS installed the ON switch is no longer required. The MARK-3 unit is, hence, always ready
to start. However, the DOS incorporates an OFF switch which the operator can activate when needed.

INSTALLATION
The DOS uses one single wire making installation simple. The DOS easily installs on the side of the
fan cowl above the carburetor shroud.
For end users with the current MARK-3 CDI units with (B-6288) mechanical cut-out switch the
necessary kit required in order to convert to DOS is B-6289. An instruction sheet for installation
purposes is provided with every kit. Please refer to Appendix (DOS Instruction Sheet).

NOTE
The DOS feature is available exclusively for MARK-3 fire pumps with CDI units that is, units
with an electronic ignition module (any MARK-3 purchased after November 2003). The DOS
became a standard feature for all MARK-3 units back in June 2009 with the
exception of the MARK-3 GSA version.

Wildfire strongly recommends using a robust type spark plug connector

CDI OEM model R-650 (refer to image) when operating the MARK-3 with
Electronic Ignition Module the DOS. This OEM spark plug connector (R-650) has been thoroughly
tested and approved for usage on our MARK-3 as a result of its signal
shielding capability which ensures the proper operation of the DOS.
Usage of another type of spark plug cap may lead to a potential DOS
malfunction and will inherently limit any applicable warranties.
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REGULAR MAINTENANCE CHECK LIST 9. Check fuel line and fittings for signs
Regular maintenance is a schedule of continous of wear, etc.
MAINTENANCE systematic maintenance, designed to prevent 10. Check and grease pump end
frequent or major breakdowns before they (as per instructions in previous section).
occur. 11. Check starter cable and mechanisms and
Maintenance on a fire pump unit should replace if it shows signs of wear.
not be done on the fire line. Always, check 12. Check condition of buffer coupling.
your pump unit immediately after use. 13. Operate pump unit and check general
1. Clean unit thoroughly. performance. Adjust carburetor if necessary
2. Clean air filter. ( (See Carburetor Adjustment page 26).
3. Clean fan housing and air intake screen. 14. Check carburetor adjustments.
4. Make sure cooling passages and cylinder 15. Note any performance irregularities or any
fins are clean. abnormal mechanical sounds.
5. Make sure spark plug is cleaned and has 16. Make sure pump seal is not leaking.
proper gap setting. 17. Make sure that all necessary tools, spares
6. Check stop switch for proper operation. and accessories are with pump unit. It is
7. Check throttle and choke control for proper strongly suggested to always have an extra
operation. spark plug on hand.
8. Make sure carburetor fuel strainer screen 18. Make sure electronic ignition module is
is clean. free of debris. Verify condition of wiring
and connections.
Ref. # Part # Description Qty
_ R-900 Maintenance tool kit (incl. all parts listed below) 1
1 PART-117* Grease gun 1
2 271-923 Wrench - adjustable 8" (203 mm) 1
3 R-911M Wrench - box & open end 1/2" (13 mm) 1
4 R-906M Wrench - box & open end 3/8" (10 mm) 1
5 R-910 Wrench - open end 1/2"-9/16" (13-14 mm) 1
6 R-902 Screwdriver 2" (51 mm) 1
7 R-904 Wrench - spark plug 1
8 A-3023 Carburetor adjusting tool 1
9 R-901 Screwdriver, 4" (102 mm) sq. handle 1
10 R-903 Feeler gauge - spark plug & breaker point 1
11 R-908 Wrench - open end 5 & 8 mm (ignition) 2
12 R-905 Handle - rod 1
13 271-488 Bag - tool roll (not shown) 1
14 271-928 6 mm T-handle Hex 10.5" LG 1
* Not required for pump ends with maintenance-free sealed bearing.

5
2 10
14

6
1
7 8

12 9
11
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REGULAR SERVICING SPARK PLUG

MAINTENANCE Operating with a defective or incorrect spark plug will affect the engine's performance and can cause
hard starting, fouling, missing, overheating, pre ignition and/or lack of power. To service and inspect
the spark plug, the following steps must be performed.

1. Remove spark plug cover.

2. Disconnect spark plug cable and remove spark plug.

IMPORTANT 3. Clean spark plug and inspect carefully. If tip of insulator core is rough, cracked, broken or blistered,
or if electrodes are burned away to the extent that they are too thin and cannot be satisfactorily
Refer also to section on
adjusted to recommended gap. 0.016" -0.020" (0.41-0.51mm), replace with new plug.
"Servicing Carburetor"
for additional "Trouble Note: Use R-629 spark plug.
Data" and service Use only spark plug type specified by engine manufacturer.
information.
4. Reinstall spark plug. Start threads one or two turns with fingers to avoid danger of cross threading.
Tighten spark plug to recommended torque of 25 Nm (18 ft-lbs or 215 inch-lbs).

5. Connect spark plug cable.

6. Install spark plug cover; tighten screws securely.

Caution: Ceramic insulation of spark plug is easily damaged by shock stresses or bending
stresses as may be imposed by dropping, striking with hard objects or overtightening. Therefore,
if spark plug has been subjected to such accidental abuse, it should be carefully inspected and tested
before further use.

UPGRADED SPARK PLUG CAP

For years the MARK-3 was using a rubber spark plug connector R-650. The rubber
connector was known to crack where the wire goes into the connector and where the rubber
connector goes onto the spark plug.
The rubber connector has since been replaced by a robust type of connector used on high
performance recreational vehicles. The connector has the added benefit of being able to shield
against noise signals.
The part number remains R-650.

A robust type of connector has replaced the old

spark plug rubber cap.
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REGULAR ELECTRONIC IGNITION UNIT

MAINTENANCE Procedure:

• Remove old flywheel and armature plate.

• Fit the new armature plate so that the long holes are aligned
, then turn it approx. 1 mm
counter-clockwise, then tighten the 3 screws. 

2 • Turn crankshaft until the piston is 3.75 mm before top dead centre, measuring through the spark
1 plug hole with a dial gauge. For the final dynamic ignition timing check make an ink mark on the
coupling buffer 12-17  as well as on the flange – pump mounting R-136. 

• Fit electronic box. 

• Start engine and check ignition timing with a stroboscopic lamp. The 2 marks  previously
made must correspond at 3000 – 4000 r.p.m.

• If the 2 marks do not correspond, remove flywheel and loosen the 3 screws  of the armature
plate, turn armature plate slightly in the direction needed. Repeat the procedure until the marks
correspond.

• Seal rubber grommet  with Silastic.

4
3

TO SPARK PLUG

TO GROUND (RED)

TO COIL (GREEN)

5
TO STOP & CUT-OUT
SWITCHES (BLACK)
OR TO DOS

MUST BE INSERTED BEFORE

INSTALLING ELECTRONIC BOX
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REGULAR ELECTRONIC IGNITION MODULE SETTINGS

MAINTENANCE
Table System Part number
Resistance value Check Ø116 mm Flywheel magneto 492.19.6009
Resistance value Check CDI unit with H.V. coil 432.39.9510

FLYWHEEL MAGNETO
+/- Green wire Ground (stator)
Green wire - 225 ÷ 255 Ω
Ground (stator) 225 ÷ 255 Ω -

CDI UNIT WITH INTEGRATED IGNITION COIL

+/- STOP VERDE Ground H.V. output
testing pin (G) (red wire) (AT)
STOP - ≤ 0.1 Ω ≥ 50 MΩ ≥ 50 MΩ
VERDE (G) ≤ 0.1 Ω - ≥ 50 MΩ ≥ 50 MΩ
Ground ≥ 50 MΩ ≥ 50 MΩ - 4.7 ÷ 5.5 KΩ
H.V. output. ≥ 50 MΩ ≥ 50 MΩ 4.7 ÷ 5.5 KΩ -

NOTES

• Testing Temperature: 25 °C.

• Values (in ohm) detected by Tester Digital BECKMAN RMS 3030.

• The above said values are not always a guarantee of perfect efficiency of the part.

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REGULAR FOR UNITS EQUIPPED WITH A DECOMPRESSION SWITCH

MAINTENANCE
DECOMPRESSION SWITCH R-233DS
The MARK-3 model MK3-DTQS features a decompression switch that significantly facilitates starting
the pump.
To convert an existing MARK-3, simply replace the cylinder head with a R-233DS (cylinder head
with decompression switch assembly)

KEY CHARACTERISTICS

• Decompression switch makes easy pulling / starting of recoil starter.

• Engine fires up easier

• No kick back
R-233DS • Easily engaged, simply push decompression switch in

• Automatically disengages / closes when engine starts

PARTS BREAKDOWN
• Decompression Switch: A-7627

• Copper Washer: A-7628

• Cylinder Head: R-233 (machined head not sold separately)

A-7627 • Head Gasket: R-238 (not shown)

A-7628 INSTALLATION NOTES

• Torque value for decompression switch: 190-210 in-lbs (21-24 Nm).

Note: The decompression switch and cylinder head must be cool prior to installation.
The threads on the decompression switch and on the cylinder head must also be clean.

• Install cylinder head with decompression switch oriented towards pump end.

R-233

Exploded view R-233DS

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REGULAR SERVICING CARBURETOR

MAINTENANCE

10
3 2 1 31

19
9
8 11 32 35 36 37 38
7
33 39
12
4 33
40
15 14 13 34
6
5
41

18
42
17
19
16

20

21

22

23

24

25

26

27

28

29

30
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CARBURETOR DESCRIPTION

Ref. # Part # Description Qty The carburetor can be cleaned with a minimum of tools. Before
disassembling carburetor it is imperative to flush it clean of
– R-1050 Repair parts kit – dirt by using proper carburetor cleaner.
– R-1115 Carburetor –
1 R-1045 Body 1 1. Remove strainer cover retaining screw and plastic cover.
2 R-1113 Carburetor gasket, isolating flange 1 2. Remove strainer cover gasket and strainer screen.
3 R-1041* Mach. screw with lock washer 2 3. Remove screws and fuel pump body.
4 R-1040* Throttle shutter 1 4. Remove fuel pump diaphragm and gasket.
5 R-1035 Throttle shaft and lever 1 5. Remove main diaphragm cover plate.
6 R-1039 Throttle shaft return spring 1 6. Remove main diaphragm and main diaphragm gasket.
7 R-1036 Throttle shaft clip 1 7. Remove inlet control lever fulcrum pin, lever and tension
8 R-1037 Lock washer 1 spring.
9 R-1038* Machine screw 1 8. Remove inlet needle.
10 R-1111 Bolt 1 9. With a thin wall 8 mm (5/16") hex socket carefully remove
11 R-1101* Throttle link lever assembly 1 the inlet seat. Remove inlet seat gasket. When reinstalling
12 R-1110* Nut 1 seat, tighten only to 3 or 4 Nm (25-35 inch-lbs).
13 R-1005 Choke shutter 1 10. Remove idle and high speed mixture screws.
14 R-1002* Choke friction pin 1 11. When reinstalling O-ring type adjusting screws, lubricate
15 R-1003 Choke friction spring 1 with SAE-30 oil to prevent seizing. Packing spring type
16 R-1004 Choke shaft and lever 1 adjustments do not require lubrication.
17 R-1001 Body channel welch plug 1 12. The ball check type main nozzle can be removed by
tapping it out of the body casting into the venturi with a
18 R-1034 Nozzle check valve 1
small punch. A replacement ball check nozzle should be
19 R-1025N Inlet control lever 1 pressed into the casting. The brass cage should be pressed
20 R-1008 Diaphragm gasket 1 flush with the metering chamber casting.
21 R-1009 Diaphragm 1
Before reassembling the carburetor (in reverse order as
22 R-1010 Diaphragm cover 1
outlined above) wash all component parts in carburetor
23 R-1011 Fuel pump gasket 1 cleaner and blow off with compressed air. The channels in the
24 R-1012 Fuel pump diaphragm 1 metering body should be cleaned by blowing through the idle
25 R-1013 Fuel pump body 1 and main adjusting orifices. All fuel passages in the three
26 R-1015 Fuel strainer screen 1 castings should be cleaned with compressed air.
27 R-1016 Fuel strainer cover gasket 1 Do not clean orifices or passages with wires or drills as
28 R-1017 Fuel strainer cover 1 this might damage and cause incorrect operation of the
29 R-1018 Machined screw 1 carburetor.
30 R-1014* Mach. screw with lock washer 6 When reassembling the inlet control lever and spring, make
31 R-1025NA Inlet control lever fulcrum pin 1 sure that the spring rests in the well of the metering body and
32 R-1029 Inlet tension spring 1 locates on the dimple of the inlet control lever.
33 R-1046N Inlet needle and seat 1 Do not stretch spring. Inlet control lever is properly set when
34 R-1025NB* Inlet control lever pin lock screw 1 flush with floor of diaphragm chamber.
35 R-1047 Inlet seat gasket 1 Be certain main diaphragm, gasket and cover casting are
36 R-1022 Idle speed screw O-ring 2 carefully fitted over the three small pins cast in rim at bottom
37 R-1021 Flat washer, brass 2 of metering body. Also the fuel pump gasket, diaphragm and
38 R-1020 Idle / High speed mixture screw spring 2 fuel pump body are placed over similar pins at bottom rim of
39 R-1019 Idle mixture screw 1 main diaphragm cover casting. Evenly tighten fuel pump body
retaining screws to insure complete seal of casting separations
40 R-1030 High speed mixture screw with pin 1 at both diaphragms.
41 R-1024* Idle speed screw spring 1
42 R-1023* Idle speed screw 1 Frequent cleaning or replacement of the fuel strainer screen
will aid satisfactory operation of the carburetor.
*Please note that these parts are not sold as spare parts.
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REGULAR SERVICING CARBURETOR

MAINTENANCE
CARBURETOR ADJUSTMENT

The carburetor is provided with three adjustments, namely high speed (main) adjustment; low speed
(idle) adjustment; and idle speed regulating screw.

1. Before starting pump unit, close both main and idle adjustment screws, by turning clockwise,
until needle just touches seat.
Note: Turn adjustment screws carefully and gently. Do not force needle into seat, otherwise, both
needle and seat may be permanently damaged.

2. Open main adjustment screw 1 turn, by turning counterclockwise.

3. Open idle adjustment screw 1 turn, by turning counterclockwise.

4. Turn idle speed regulating screw until throttle shutter is slightly open.

5. Start unit. Open choke slowly, and allow engine to warm up thoroughly, gradually
increasing speed to full throttle setting while running with 6 mm (1/4") diameter nozzle tip
connected to a 3 m (10') discharge hose.

6. When engine is thoroughly warmed up, close throttle, then adjust idle adjustment screw and idle
speed regulating screw, until engine idles smoothly between 2000-2200 RPM.

7. Increase speed gradually to full throttle setting, then turn main adjustment screw until engine
gives maximum RPM and pump delivers maximum pressure. Then, turn main adjustment screw
1/4 turn maximum counterclockwise. This setting will give correct mixture ratio to assure proper
engine lubrication.
Do not leave main adjustment screw set too lean, otherwise serious engine damage may occur due
to lack of sufficient lubrication.
Note: It will be necessary to readjust the carburator when taking the pump from one altitude and
placing in a different altitude. Repeat steps 1 to 7.

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REGULAR MAINTENANCE

CARBURETOR TROUBLESHOOTING CHART

CARBURETOR FLOODING
Possible cause Remedy
Dirt or foreign particles preventing inlet needle from seating. Remove, clean and replace.
Diaphragm lever spring not seated on lever dimple. Remove lever and reinstall.
Diaphragm improperly installed in carburetor. Replace diaphragm or correct installation.
Improper use of choke Proper use of choke at start-up

ENGINE WILL NOT ACCELERATE

Possible cause Remedy
Idle adjusting screw set too lean. Enrich idle adjustment.
Incorrect setting on diaphragm lever. Reset.
Diaphragm cover plate loose. Tighten.
Diaphragm gasket leaking. Replace.
Main fuel orifice plugged. Remove diaphragm cover, diaphragm, diaphragm lever and main
adjusting screw. Clean out orifice by blowing through main
adjustment threaded hole.

ENGINE WILL NOT IDLE

Possible cause Remedy
Incorrect idle adjustment. Reset to best idle.
Idle discharge ports or channels clogged. Blow out with compressed air, or if compressed air is not available,
clean and flush with gasoline.
Diaphragm lever set incorrectly. Reset diaphragm lever so it is flush with the floor of the diaphragm
chamber.
Throttle shutter cocked in the throttle bore causing fast idle. Reset.
Dirty nozzle check valve. Clean and/or replace.
Welch plug covering the idle discharge ports does not seal. Replace welch plug.
This causes the engine to idle with idle adjustment shut off.

ENGINE RUNS OUT LEAN

Possible cause Remedy
Tank vent not working properly. Clean and/or replace.
Leak in fuel system from tank to pump. Tighten or replace fittings or lines.
Ruptured fuel pump diaphragm. Replace.
Main fuel orifice plugged. Clean.

CARBURETOR RUNS RICH WITH MAIN ADJUSTMENT SHUT OFF

Possible cause Remedy
The nozzle channel plug, or nozzle check valve cage, is not sealing. Install new plug or new cage.
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AIR FILTER

Ref # Part # Description Qty 12 13 14 15

1 R-793 Mach. screw, stainless steel, 2

nylon insert
2 R-791 Lock washer, steel, plated 2 1 2 3
3 R-1044 Lock plate 1
4 R-794 Cover for air filter 1
11
5 R-955 Air filter element - foam & screen 1
6 R-790 Carburetor shroud 1
(includes decal A-4030)
7 12-79 Lock washer, steel, plated 4
8 B-4036-12 Mach. screw, hex socket cap, steel 2
9 R-799 Bracket 1
10 R-774 Mach. screw, steel, plated 2
11 R-1102 Link for throttle 1
12 B-4024 Quadrant for throttle lever 1
13 R-1107 Throttle lever sub-assembly 1
14 A-4028 Spring, stainless steel 1 4 5 5 6 7 8 9 7 10
15 A-4027 Index pin 1

CYLINDER ASSEMBLY
6

Ref. # Part# Description Qty

1
2 5
1 R-150 Lock nut, steel, plated 2
3
4
2 R-149 Lock washer, steel, plated 2
3 R-402 Stud, steel 2
4 R-1113 Carburetor gasket, isolating flange 1
5 R-238 Cylinder head gasket 1
6 R-233 Cylinder head 1
7 R-235 Cylinder flange gasket 1
8 R-270 Cast iron cylinder sleeve 1
9 R-257* Cylinder 1
(incl. cast iron cylinder sleeve R-270)
10 R-237 Muffler gasket 1
11 R-117 Stud, steel 2
12 R-119 Lock washer, steel, plated 2 7 8 9 10 11 12 13

13 R-120 Nut, hex, plated 2

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REGULAR COOLING SYSTEM

MAINTENANCE
Efficient engine cooling is Ref # Part # Description Qty
accomplished by a fan attached 1 R-414 Bolt, hex, steel, plated 2
to the flywheel. This fan pulls air 2 R-119 Lock washer, steel, plated 2
through the fan housing screen,
3 R-413 Cover for spark plug 1
then forces the air around the
cylinder and through the spaces 4 R-408 Mach. screw, steel, plated 1
between the cylinder and 5 12-38 Lock washer, stainless steel 3
cylinder head fins. 6 R-409 Ignition cable clamp, steel, plated 1
7 R-411P Fan cowl with studs, painted (incl. R-115 & R-402) 1
In time the cooling air passages
8 R-115 Stud, steel 3
will become partially clogged
and the fins will become coated 9 R-402 Stud, steel 1
with dirt and thereby reducing 10 R-418 Fan shield, steel, painted 1
the cooling efficiency. 11 R-150 Lock nut, steel, plated 2
12 TY-1811 Lock nut, steel, plated 2
Therefore, whenever this
13 R-151 Flat washer, steel, plated 1
condition occurs, remove fan
housing then use compressed
air or a stiff bristle brush and
appropriate cleaning solution to
remove all dirt deposits from fins 1 2 3
and from inside the fan housing.

4 5 6 7 10

11 8

12 5 8
12 5 8

11 13 9
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REGULAR REWIND STARTER

MAINTENANCE
Ref # Part # Description Qty
-- R-529 Rewind Starter Assembly
1 R-518 Circlip, steel 1
2 R-517 Flat washer, steel, plated 1
3 R-516 Friction spring, steel 1
4 R-526 Friction washer, steel 1
5 R-528 Pawl assembly 1
6 R-510 Flat "D" washer, steel 1
7 R-504 Sheave for starter rope 1
8 R-506 Rewind spring 1
9 R-531 Rewind spring retainer 1
10 R-530 Starter housing 1
11 12-38 Lock washer, stainless steel 4
12 R-522 Mach. screw, steel, plated 4
13 R-524 Mach. screw, steel, plated 2
14 R-523 Lock washer, steel, plated 2
15 R-532 Rewind starter cover 1
16 R-509 Plug 1
17 R-505 Lock pin 1
18 R-502 Starter rope 1
19 R-533 Starter rope guide 1
20 R-544 Rubber buffer 1
21 R-501 Rewind starter handle 1

21
14
13 15

20

19

18

NOTE 16
17
Pawl assembly #5 must be
assembled with the
pawl-spring-stop on the left,
otherwise the starter will not
function.

4
3
2
1 12
9
11
10

8
5 6 7
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REGULAR SERVICING THE REWIND STARTER

MAINTENANCE
WARNING
All repairs must to be carried out by qualified, professionally trained and authorized
mechanics. Only careful assembly and the respecting of the instructions found in this
SERVICE MANUAL will ensure trouble free operation.

12 12
• Remove 4 hex. screws M6x20 and lock washers and detach the rewind
starter assembly.

12 12

• Depress the cover washer  and remove circlip
.

1

4 3

• Remove cover washer , friction spring  and friction washer .

• Remove rewind starter parts set ass’y  and thrust washer.
5
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REGULAR SERVICING THE REWIND STARTER (continued)

MAINTENANCE

13 • Hold rope sheave  and remove the 2 screws

along with lock
15 washers and the cover  with plug .

Warning: Keep rope sheave  firmly in hands! Risk of injury when rewind
spring  unwinds!
16

21
• Pass the starter handle
21 through the window in the starter housing and turn rope
sheave  approx. 4 turns counterclockwise so that the rewind spring  unwinds.

• Remove starter sheave  with starter rope 

18 and starter grip 21 .
18
7

• Check bearing bolt 

22 for signs of seizure.
8
4
Note: If there are slight signs of seizure remove them carefully.

• Check bearing bore of the rope sheave  for signs of seizure.

22 Note: If there are signs of seizure the rope sheave must be replaced.

• Apply oil on the rewind spring .

• Apply Molykote G-N slide paste on the bearing bolt 

22 of the rope sheave .
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SERVICING THE REWIND STARTER (continued)

19
• Wind starter rope  fitted with starter handle
21 counter-clockwise in the rope
sheave .

• Fit rope sheave  on the bearing bolt and engage it by slight turning into the
16 rewind spring .

• Hold rope sheave firmly and turn starter housing 4 turns clockwise to pretension
the rewind spring.
7 • Fit rope guide  in the recess and pass the starter grip through the window in
13 the starter housing, holding the rope sheave firmly.
15
• Fit the plug .

• Fit the cover  and fix it with 2 screws

and lock washers .
16
Tightening torque: 2.2 - 3 lb-ft (3 - 4 Nm)

5 • Insert thrust washer .

24 • Fit rewind starter parts set ass’y  in the rewind starter.

23 Note: Pay attention to correct positioning. The corners of the pivot arm 
23 must
point toward top / left 24 and down / right 25 .

25 • Slightly lubricate the serration 

23 of the pivot arm.

• Insert the friction washer  so that the serration points towards pivot arm 
23 .

• Fit friction spring  and cover washer .

3
10
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REGULAR SERVICING THE REWIND STARTER (continued)

MAINTENANCE

• Depress cover washer  and fit circlip
.

8

• Pull starter handle

21 and check whether the pawls 23 24 are moving outward.
When releasing the starter grip the starter rope must be rewound to its idle
24 position.
Note: If the pawls do not move outward, the rewind starter parts set ass’y
 has been inserted wrongly. In this case disassemble it again and fit the
rewind starter parts set ass’y correctly.
23

• Fit rewind starter assembly with 4 hex. screws and lock washers.
Tightening torque: 6.6 lb-ft (9 Nm)
12 12
• Start engine to check function of the rewind starter.

12 12

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REGULAR Ref. # Part # Description Qty

MAINTENANCE 1 R-116 Lock nut, steel, plated 6
2 R-667N-E Flywheel magneto assembly 1
3 R-603 Fan 1
MAGNETO
4 R-791 Lock washer, steel, plated 4
To check if ignition system is functioning, 5 R-146 Mach. screw, steel, plated 4
remove spark plug and connect another 6 R-602 Stud, steel 3
spark plug, with gap set to 3.2 mm 7 R-653 Pulley gasket 1
(0.126"), to the ignition cable. With this 8 R-601 Pulley for manual start 1
plug resting on top of cylinder head,
9 12-38 Lock washer, stainless steel 3
give starter rope a normal pull. Spark
should easily jump the gap, if system is
functioning properly.

If no spark appears: 5
Check stop switch and cable for possible short 4
Check for shorted condenser 3
Check for open coil
Check for broken leads or cables
Check electronic ignition module 2
Check DOS

If spark is weak: 1 1
Check magneto air gap 9
Check electronic ignition module
8

7
6

SERVICE TOOL KIT

Ref. Part Description Qty

# #
1
_ R-952 Service tool kit 1 7
(incl. all parts listed below)
1 R-929 Flywheel holding tool 1
2 271-927 Screwdriver 1
Phillips No.12 4

3 271-346 Screwdriver - standard 1

4 R-928 Cap - shaft protector 1 2 3
8
5 R-930 Puller - crankshaft 1 11
bearing R-313 5
6 R-938 Puller - crankshaft 1 9
bearing R-333
7 R-932 Puller - collar coupling 1 12
8 R-933 Oil seal - pressing tool 1
9 R-927 Puller - magneto 1
10 R-953 Crankshaft jack 1 10
13
11 R-954-14 Gauge - timing 1 6
12 R-926 Socket wrench 1
14 mm (9/16")
13 R-909 Key - Allen 1
2.4 mm (3/32")
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REGULAR SERVICING MAGNETO

MAINTENANCE
Before replacing flywheel assembly, the ignition timing should be checked.
See "Ignition Timing".

Ref. Part Description Qty 1. Replace flywheel assembly; make certain that flywheel keyway is aligned properly with
# # crankshaft key.
_ R-656 Armature 1
plate complete
Important: Remove all traces of grease, oil and dirt from crankshaft taper and flywheel
(incl. parts with *) bore before replacing flywheel assembly.
1 R-665* Mach. screw 1 2. Replace lockwasher and flywheel hub nut.
2 R-611* Lockwasher 1
3 R-637* Flat washer 1 3. Tighten hub nut to recommended torque. This is very important.
4 R-664* Point & cable 1 4. Attach fan cowl assembly.
condenser R-628
5 R-655* Mach. screw 2 5. Attach spark plug cable clamp.
6 R-611* Lockwasher 2
6. Connect cable to stop switch.
7 R-637* Flat washer 2
8 R-661* Coil 1
9 R-638 Mach. screw 3
4 5 6 7 8
10 R-611* Lockwasher 3
11 R-637 Flat washer 3
12 R-662* Condenser 1
13 R-659 Armature plate 1
(incl. R-662)
14 R-654* Cap 1
1 2 3
15 R-636* Grommet
16 R-630* Cable-spark plug 1
Cable- spark plug
17 R-645 Rubber sleeve 1
18 R-650 Protector - spark plug 1
19 R-629 Spark plug 18 mm 1
_ R-633T Stop switch kit 1
(incl. Ref. #20 to #25)
20 R-665 Mack, screw 1
21 R-637 Flat washer 1
22 R-611 Lock washer 1 9 10 11
23 C-7010-12 Stop switch assembly 1
24 12-79 Tooth lock washer 1 Note: Armature plate for pointed engine shown
12 13
25 C-7010-12C Connector 1
26 R-634* Cable stop switch 1
R-633T
14 15 16 17 18

19

20 21 22 23 24 25 26
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ENGINE OVERHAUL Ref. # Part # Description Qty

SERVICE PROCEDURE 1 R-146 Mach. screw, steel plated 4
2 R-144 Dust shield 1
3 R-132 Mach. screw, hex socket cap, steel, plated 3
4 R-105 Mach. screw, hex socket cap, steel, plated 2
DISASSEMBLY AND ASSEMBLY 5 12-38 Lock washer, stainless steel 5
PROCEDURES OF ENGINE 6 R-342 Oil seal, 25 mm 1
This procedure outlines how to 7 R-103 Dowel tube, steel, plated 2
conduct major overhaul service to 8 R-133 Crankcase gasket 1
the MARK-3 engine. It lists all 9 R-123 Oil seal, 20 mm 1
instructions to replace or service the 10 R-236 Stud, steel (cylinder mounting) 4
following components: 11 R-206 Flat washer, steel, plated 4
12 R-120 Nut, hex, plated 7
• Crankshaft-connecting rod assembly;
• Crankshaft ball bearings; 13 A-6149P Mounting leg 4
• Crankcase; 14 R-130 Stud, steel 4
• Oil seals; 15 R-113 Bronze gasket 1
16 FAST-51 Drain screw, socket cap, steel, plated 1
DISASSEMBLY OF THE ENGINE FROM 17 R-117 Stud, steel 3
THE MARK-3 18 R-136 Pump mounting flange 1
1. Remove pump end assembly and flexible 19 C-5370-11 Flat washer, stainless steel 1
buffer coupling disc. 20 RA-108 Bolt, hex, steel, plated 1
2. Remove all wiring. 21 R-119 Lock washer, steel, plated 3
3. Remove clamp, which holds spark plug 22 R-152 Crankcase halves set complete w/ 2 dowel tubes (R-103)
cable to fan cowl.
4. Remove bracket R-799, which fastens to
side of carburetor shroud to engine
crankcase.
5. Remove engine from mounting frame.
6. Remove muffler.
7. Remove fan cowl with rewind starter.
8. Remove spark plug cover and spark plug.
12
9. Using the flywheel holding tool R-929
13
(Refer to the “Service tool kit” section), to
prevent the collar coupling from
rotating; remove nut and lockwasher
22 10
from the collar coupling.
10. Remove collar coupling from engine with 8
collar coupling puller R-932.
9
11. Remove manual starter rope pulley.
12. Remove flywheel nut and lockwasher 22 7
using flywheel holding tool R-929. 6 19 20 21 12
13. Remove flywheel/magneto/fan using 18
magneto puller R-927 and shaft 17
protector tool R-928.
5

2 3

1 15
16

14

13
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MAJOR OVERHAUL Ref. # Part # Description Qty

SERVICE R-348 Crankshaft/Conn. Rod with Kit (includes parts with * ___
and R-342 oil seal. R-346 and R-347 (shims not shown).
DISASSEMBLY OF THE ENGINE 1 R-303 Nut, hex, plated (flywheel side) 1
1. Remove the key R-305. 2 R-301 Lock washer, steel, plated 2
2. Mark the position of the armature plate. 3 R-343 Ball bearing, 25 mm (flywheel side) (1 piece bearing) 1
4 R-344 Shim, .0044", steel (flywheel side) 1
3. Remove armature plate with cables.
5 R-305 Key 1
4. Remove the cylinder head, the cylinder
6 R-324 Needle bearing 1
and the crankcase studs.
7 R-328 Gudgeon pin 1
5. Remove piston from connecting rod. 8 R-331-1 L-type piston ring 1
6. Remove the machine screws, which fas- 9 R-331 Piston ring .078" 1
ten crankcase halves together. 10 R-332 Piston with rings 1
7. Remove the rubber seal located on the 11 R-329 Circlip 2
housing. 12 R-341 Crankshaft/connecting rod sub-assembly 1
8. To separate crankcase halves on engine 13 R-334 Spacer, steel, plated 1
with one-piece bearing, heat both 14 R-306 Shim, .006", steel (coupling side) 1
crankcase halves (on the outside face 15 R-333 Ball bearing, 20 mm (coupling side) (1 piece bearing) 1
of the crankcase around the bearing 16 12-18 Coiled spring pin, steel 4
housing portion) to a maximum of 17 R-315 Coupling collar 1
100 °C (212 °F) and, using a plastic
18 R-302 Nut, hex, plated (coupling side) 1
or rubber mallet, separate crankcase
halves.
9. Remove crankshaft with connection rod.
10.Press out both oil seals using oil seal
pressing tool R-933.
11.Remove bearings. To remove from crank-
shaft journals using shaft protector tool
R-928 and bearing puller tool R-938.
16
18
7 8 9 10 11 2
17

15
14
13

12

6
5
4
3
2
1
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MAJOR OVERHAUL REASSEMBLY SERVICE FOR ENGINE

For reassembly (1 piece bearing)
SERVICE
1. Place both crankcase halves on a table with inner faces up.
Pistons, rings and shims optional sizes 2. Using a depth micrometer, carefully check the distance from joint-face of each
R-307 Shim 0.008" As req. crankcase half to lower face of each bearing housing.
(coupling side) 3. For pump side crankcase half, call this dimension (A) (see image).
R-308 Shim 0.012" As req. 4. For magneto side crankcase half, call this dimension (B) (see image).
(coupling side)
5. Measure thickness of crankcase gasket R-133. Call this dimension (C).
R-309 Shim 0.016" As req.
(coupling side) 6. Add (A) + (B) + (C). Call this dimension (D).
R-310 Shim 0.020" As req. 7. Measure the thickness of ball bearing R-333. Call this dimension (E).
(coupling side) 8. Measure the thickness of ball bearing R-343. Call this dimension (F).
R-311 Shim 0.031" As req. 9. Measure the thickness of crankshaft spacer R-334. Call this dimension (G)
(coupling side)
10. Measure the width of the crankshaft between both bearing thrust surfaces. Call this
R-312 Shim 0.040" As req. dimension (H) (refer to image).
(coupling side)
11. Add (E) + (F) + (G) + (H). Call this dimension (I).
R-344* Shim 0.004" As req.
(flywheel side) 12. Subtract (D) – (I) and call this dimension (J).
R-345* Shim 0.012" As req. The dimension (J) is the total axial clearance on the crankshaft. The acceptable axial clear-
(flywheel side) ance is from .0079” to .0118”. The average acceptable axial clearance is therefore .0098”.
R-346* Shim 0.020" As req. 13. Subtract (J) = (average acceptable clearance .0098”) = total shim thickness
(flywheel side)
14. Put the spacer on the crankshaft (pump side).
R-347* Shim 0.039" As req.
(flywheel side)
15. Put the shims on the crankshaft magneto side (fan).
R-332-0 Oversized piston Note: The crankshaft used in the electronic ignition units does not have a lobe
– ground into the crankshaft end.
(includes rings)
R-331-0 Oversized piston ring 0.078" – 16. Apply a small amount of Anti Seize (Copaslip or Loctite) on the ball bearing R-333.
R-331-0-1 Oversized L-type piston ring – 17. Heat the ball bearing to a temperature of 90 °C (194 °F) not exceeding 100 °C
R-321 Serrated lockwasher 12 mm (212 °F).
–
(used on old style engine)

DETERMINE THE TOTAL THICKNESS OF SHIMS

Acceptable average axial
Total thickness of shims =J- clearance (.0098”) J =D-I

A B

D =A+B+C
Shim (C)

F Magneto side H Pump side G E

Shim

I=E+F+G+H

Bearing R-343 Spacer R-334 Bearing R-333

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MAJOR OVERHAUL 18. Install the ball bearing R-333 on the crankshaft (pump side). If necessary use a
pressing tool to insert the bearing on the crankshaft.
SERVICE 19. Apply a small amount of Anti Seize (Copaslip our Loctite) on the ball bearing R-343.
20. Heat the ball bearing to a temperature of 90 °C (194 °F)
not exceeding 100 °C (212 °F).
21. Install the ball bearing R-343 on the crankshaft (magneto side). If necessary use a
pressing tool to insert the bearing on the crankshaft.
22. Heat the crankcases to a temperature of 90 °C (194 °F) not exceeding 100 °C (212 °F).
23. Install the new oil seals R-123 on the coupling side (pump side) and R-342 on the
magneto side (fan) of the crankcase. The oil seals must be installed from the inside to
the outside with the closed side facing the exterior of the crankcase.
24. Grease the oil seals.
25. Slide crankshaft in crankcase half (pump side). Be careful to prevent damage to lip
of oil seal.
26. Important : Ensure that the rotating part of the bearings do not come into
contact with the seals.
27. If necessary press crankshaft into crankcase half (pump side). To prevent bending of
crankshaft, be sure to always use tool R-953 (fig. 1), crankshaft jack, between webs
of crankshaft (fig. 2).
28. Install a new crankcase gasket R-133, apply some oil.
29. Slide the other crankcase half on crankshaft.
30. Align dowel tubes and verify that crankshaft jack and connecting rod are in piston
axe (fig. 3) and press crankcase halves together.
31. Cool the crankcases to a temperature of 20 °C (68 °F) before installing the crankcase
screws.
32. Reassemble crankcase screws and lockwashers. Tighten screws uniformly to 10 Nm
(90 inch-lbs) torque.
33. For stress relief, gently tap the two crankcase halves with a soft head hammer.
34. Turn crankshaft and check for smooth run.
35. If piston was removed, reinstall it in proper position (arrow on top of piston or bal-
ancing lumps inside piston head should be on muffler side of engine). Replace nee-
dle bearing R-324, if necessary.
36. Change cylinder head and cylinder flange gaskets (R-235 and R-238). The cylinder
head gasket must have the large band up.
37. When reassembling cylinder head, be sure the “filled”
part inside the head is on the muffler side of the engine, therefore the “scooped-out”
part will be on the carburetor side).
Important: Put carburetor side on same side of spark plug cable hole in
crankcase. Tighten cylinder head nuts to recommended torque as 23-25 Nm
(200-220 inch-lbs). Nuts should be torqued after first 10 hours of operation and
every 100 hours after.
38. Reassemble remaining parts in reverse procedure used in disassembly.

F Magneto side H Pump side G E

Shim

Bearing R-343 Spacer R-334 Bearing R-333

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MAJOR OVERHAUL Ref. # Part # Description Qty

SERVICE 1 12-42 Mach. screw, stainless steel, nylon insert 1
2 12-38 Lock washer, stainless steel 9
3 12-13 Nose for shaft 1
DISASSEMBLY PROCEDURE 4 A-5537 Protective cap, suction 1
FOR PUMP END 5 12-39 Mach. screw, stainless steel 8
1. Remove shaft nose #3, by removing 6 12-12A Suction cover with bronze bearing 1
screw #1, and lockwasher #2. These 7 12-27 O-ring 1
will be visible upon removal of 8 12-43 Gasket 1 1/2" (38 mm) 1
suction protective cap. 9 12-10 Cap for priming port 1
10 A-5538 Retainer for priming cap 1
2. Remove screws #5, and
11* 12-29 Grease fitting 1
lockwashers #2.
12* 12-87 Extension for grease fitting 1
3. Using tool A-1888, remove suction 13* FAST-722 Set screw, stainless steel 1
cover #6. 14 A-5536 Protective cap, discharge 1
4. Bend lockwasher #19 from locknut 15 12-73 Plug, 1/8" NPT, brass 1
#18. Using tool R-904L or 19 mm 16 12-8 Pump body, 12-16 / 12-16S (4-stage) 1
(3/4") wrench, remove locknut and 17 12-28NS Mechanical rotary seal 1
lockwasher. -- A-2688 Thread protector 2" NPSH (suction) (incl. gasket) Optional
5. Remove screws #28. -- ADP-A-FM15S Thread protector 1 1/2" NPSH (discharge) (incl. gasket) Optional
-- A-7465 Thread protector 1 1/2" NH (discharge) (incl. gasket) Optional
6. Using bench-press and tools
-- FA-4 1/4-turn quick-connect adaptor (discharge) (incl. gasket) Optional
A-1890, A-4097 and A-5297,
press out shaft assembly. *Pump ends with the sealed double row ball bearing (12-48S) exclude
the set screw FAST-722, the grease fitting 12-29 & the extension 12-87.
7. Using seal puller A-7644, remove
seal. 11* 12* 14 15 16 17
8. Using bench-press and tools A-1886
and A-5297, remove all impellers
and distributors. Operation is done
in jogging strokes of press ram, so
that all parts will be removed in a 10
group.

1
2 3 4 5 2 6 7 13*
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MAJOR OVERHAUL ASSEMBLY PROCEDURE FOR PUMP END

SERVICE 1. Slide bearing retaining ring #27 on shaft with plain face toward coupling collar.
2. Press bearing #26 on shaft.
3. Press rotary seal #17 in pump body using sleeve A-4329. This should be done
carefully.
Ref. Part Description Qty
# # 4. Carefully pass end of shaft assembly through rotary seal bore. Make sure that the flat
18 12-50** Locknut stainless steel 1 sections of the shaft line up with the rotary seal flat sections. Gently press down the
shaft until ball bearing rests firmly against shoulder in pump body.
19 12-49** Lock washer, 1
stainless steel 5. Attach retaining ring #27 to pump body using six screws and tighten evenly and firmly.
20 12-11** Impeller 1 6. Slide impeller #23 onto shaft, and engage with seal.
21 12-9 Distributor 2 7. Place O-ring #25 in groove of distributor #24. It is important to smear the new
22 12-27 O-ring 2 O-rings with a suitable lubricant. This will facilitate the assembly.
23 12-7** Impeller 3 8. With open end of pump body in vertical position, carefully lower distributor #24
24 12-6 Distributor 1 until it rests on bottom of body.
25 12-26 O-ring 1 9. Slide impeller #23 into position, aligning with shaft.
26 12-48* Double row ball 1 10. Place O-ring #22 in groove of distributor #21.
bearing 11. Place distributor on open end of body, then using bench press and assembly tool
26a 12-48S Sealed double 1 A-1884, apply several light, downward strokes of press ram until distributor "drops"
row ball bearing into body. Distributor must then be positioned by hand as before.
27 12-3* Retaining ring 1 12. Slide impeller #23 into position, aligning with the other impeller.
for bearing 13. Repeat steps 10 and 11 for the remaining distributor.
28 12-25 Mach. screw, 6 14. Slide impeller #20 into position, aligning with previous impeller.
stainless steel,
nylon insert 15. Place lockwasher #19 on shaft with locating tab in milled groove.
29 12-2C* Shaft and collar 1
assembly, 4-stage
30 12-17 Coupling buffer 1
-- 12-2D Shaft sub-assembly,
4-stage, with impellers
(incl. parts with * and **,
7 items)
-- 12-2E Shaft sub-assembly, 4-stage 25
(incl. parts with *, 3 items)
22
22 26a

18 19 20 21

23 26 27 28 29 30

23 21 23 24
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MAJOR OVERHAUL ASSEMBLY PROCEDURE FOR PUMP END (continued)

SERVICE 16. Screw locknut #18 onto shaft. When tightening the nut, do not use excessive force as
this may result in failure of the seals, drive bushing or impellers. Do not forget to
secure the shaft from rotating. Bend lockwasher up onto one flat of the hexagon
locknut at a position approximately 180° from the milled slot in the shaft.
17. Place O-ring #7 in groove of suction cover #6, then bench press the cover into the
pump body until it rests on face of first distributor. A gap of approximately 0.794 mm
(1/32") between nozzle flange and end of body, is normal.
18. Attach suction cover to body by using the #5 screws and lockwashers #2. Tighten
screws evenly and firmly.
19. Attach shaft nose #3 using lockwasher #2 and screw #1. Tighten screw evenly and
firmly.
20. Check gasket in the priming cap #9 and replace if damaged.
21. Reinstall the suction and discharge thread protectors (if equipped).
22. Reinstall caps on suction and discharge inlets.

NOTE NOTE: Pump ends (12-16) with the double row ball bearing (12-48) should
be greased after every 8 hours of operation.
The maintenance-free sealed
bearing (12-48S) eliminates pump Use a clean gun filled with fresh grease. Remove dirt from grease fitting
failure dangers related to improper before applying grease gun. Grease should be pumped slowly into bearing
greasing by completely removing the chamber until fresh grease appears around bearing retaining ring.
need to grease the pump end bearing. Wipe off excess grease.
No greasing is necessary for pump Use only water repellent ball bearing grease, preferably a grease that has a
ends (12-16S) which have a sealed rust inhibitor.
bearing.
A grease relief valve (old style only) has been provided to prevent pressure
buildup on the rotary seal, should the fresh grease not be able to flow
completely through the bearing, due to old grease being hard packed, etc.
DO NOT use graphite grease, or a pressurized grease gun.
TOOL KIT FOR
PUMP END
Ref. Part Description Qty
# #
1
– A-2356 Tool kit for pump end – 2
1 A-1884 Pressing sleeve 1 3
4
for distributor
2 A-4329 Seal pressing sleeve 1
3 A-4097 Shaft protector 1
4 A-7644 Seal puller for 12-28NS 1
5 A-1888 Suction cover puller 1
5 6 7 8
6 A-1890 Pressing pin for 1
shaft removal
7 A-1886 Pressing pin for 1
distributor removal
8 R-904L Wrench for 1
lock nut/spark plug
9 A-1887 Shaft installation 1
aligning guide
10 A-5297 Pump support tool 1

10
9
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MISCELLANEOUS
FRAME 6

Ref. # Part # Description Qty

-- C-5200N Frame kit (incl. all parts) --
7
-- C-5200N-15 Frame hardware kit (incl. all
1
parts except C-5201 frame) --
1 C-5200-8 Bolt, hex, stainless steel 2 2 8
2 D-5269-7 Flat washer, stainless steel 2
3 9
3 C-5200-7R Rubber spacer for fuel connector 2
4
4 C-6650-14 Lock nut, steel, plated 2
5 C-4506-3 Rubber bumper 2 10
6 A-6149P Mounting leg 4 5
7 A-4005 Mounting pad 2
8 A-6179 Rubber ring 8
9 C-5200-5 Rubber washer 4
10 C-5201 Frame 1
11 C-5200-6 Flat fender washer, steel, plated 4
12 R-111 Lock washer, steel, plated 4
13 C-5200-12 Bolt, hex, steel, plated 4 8
-- C-5200RK-11 Frame kit parts list 1 11
12

13

QUICK-CONNECT FUEL LINE

Ref. # Part # Description Qty

14
-- R-1114 Quick-connect fuel line 1
(includes parts with *)
1 C-5200-8 Hex bolt 2 15

2 D-5269-7* Flat washer 2 10

3 R-798* Fuel line - plastic 1 3
4 R-706* Body quick-connect male 1
5 R-709* Elbow 1
1
6 C-5200-7R* Spacer - rubber 2 2
7 C-6650-14* Hex lock nut 2
4
8 A-7486 Dust cap male connector 1
9 A-7487 Dust cap female connector 1
5 8 11
10 R-712 Handle quick connect 1
6
11 R-732 Connector 1 7
12 FA-552Q Fuel air transport tank 1
9
13 FA-451 Fem. quick connect 1 12 13
14 12-401B-NS Hose-fuel supply 1
with priming bulb
15 12-65 Coupling swivel 1
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NOISE REDUCTION MUFFLER 8

Ref. # Part # Description Qty

1 R-237 Muffler gasket 1

2 R-151 Flatwasher,
steel, plated 1
3 R-150 Lock nut,
steel, plated 1
4 R-229 Muffler 1
5 C-5370-11 Flat washer,
stainless steel 1
6 R-119 Lock washer,
steel, plated 1
7 RA-108 Bolt, hex, steel, 1
plated 1
8 PART-205 Spark arrestor
(incl. screw) 1
6

PART-205 7
USFS Approuved Spark arrestor
2
3
4

5
DECARBONISING
After several hours of normal operation, carbon deposits will form on piston crown, cylinder
head, in the cylinder exhaust port and around piston rings and in the ring grooves, causing
erratic and faulty operation. The piston skirt may also show signs of gum and varnish deposits.
To decarbonise, the cylinder head, cylinder and piston should be removed. All carbon
deposits should be carefully removed, particularly from the piston ring grooves. After
removing carbon, wash all parts in a suitable solvent, then dry with compressed air. On
reassembly, always use new piston rings.
After every 100 hours of operation, or more often if a loss of power is observed,
the engine should be decarbonised.
To decarbonise the engine, proceed as follows:
1. Remove muffler. If muffler is very dirty internally or appears burned or cracked, it should
be replaced with a new muffler.
2. Remove cylinder head and cylinder head gasket.
3. Rotate crankshaft until piston is at bottom dead centre.
4. Using a brass scraper tool, carefully scrape carbon deposit from exhaust port. During
this operation, tilt engine so that deposits will not fall into combustion chamber.
5. Use suitable brass tool to push out any carbon deposit which may have formed in the
hole provided in the cylinder liner for bypass.
6. Rotate crankshaft until piston is at top dead centre.
7. Use a stiff (not wire) brush to remove loose, flakey carbon from top of piston. Do not
remove hard deposit of carbon, as this layer forms a natural heat insulator to protect
the piston crown.
8. Remove all carbon deposits from cylinder head.
9. Replace cylinder head. Tighten nuts uniformly to recommended torque
23-25 Nm (200-220 inch-lbs) value. Always use a new cylinder head gasket (cylinder
head gasket must have the large band up).
10. Check and replace muffler gasket if worn or damaged. Reinstall muffler.
11/2012
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PUMP
TECHNICAL SPECIFICATIONS Impeller #12-7 diameter 93.22 mm ±0.13 / 03.670" ±0.005
TORQUE VALUES Impeller #12-7 width 38.86 mm ±0.05 / 1.530" ±0.002
ENGINE Impeller #12-11 diameter 93.22 mm ±0.13 / 03.670" ±0.005
Spark plug 41 Nm / 360 inch-lbs (30ft-lbs) (41Nm) Impeller #12-11 width 34.11 mm ±0.05 / 1.343" ±0.002
Cylinder head nuts 23-25 Nm / 200-220 inch-lbs Distributor #12-6 diameter 123.39 mm-123.47 mm / 04.858"-4.861"
Should be retorqued every 100 hours of operation. Distributor #12-6 width 31.31 mm ±0.05 / 1.234" ±0.002
Flywheel hub nut 44-45 Nm / 390-400 inch-lbs Distributor #12-9 diameter 0123.39 mm-123,47 mm / 04.858"-4.861"
Collar coupling nut 11-14 Nm / 100-120 inch-lbs Distributor #12-9 width 34,11 mm ±0,05 / 1.343" ±0.002
Crankshaft with no keyway at PTO end should be Pump inside depth 108,10 mm ±0,05 / 4.256" ±0.002
torqued to 19-21 Nm / 175-185 inch-lbs. Pump ball bearing housing 51.99 mm-52.02 mm / 2.047"-2.048"
Crankcase assy. screws 11-12 Nm / 100-110 inch-lbs Nozzle bushing 19.037 mm-19.063 mm / 0.7495"-0.7505"
bearing housing
PUMP
Buffer thickness (#12-17) 8.25 mm-8.89 mm / 0.325"-0.350"
Retaining ring screws 6.7-7.3 Nm / 60-65 inch-lbs
Shaft nose screw 7.9-8.5 Nm / 70-75 inch-lbs Shaft ball bearing support 25.004 mm-25.011 mm / 0.9844"-0.9847"
Nut #12-50 28-29 Nm / 250-260 inch-lbs. Shaft bushing bearing support 12.687 mm-12.700 mm / 0.4995"-0.5000"
Suction nozzle screws 7.9-8.5 Nm / 70-75 inch-lbs Shaft maximum run-out 0.0889 mm / 0.0035"

STANDARD CYLINDER SPECS

(new sleeve for standard piston)
Cylinder bore (standard) 61.95 – 61,96 mm – 2.439 à 2.4394 SOLID STREAM NOZZLES (Approximate reach of stream)
Cylinder bore (hone) 62.00 – 62,01 mm – 2.4409 à 2.4413
Surface Roughness 1 to 2 Micron – 39 to 78 Microinches
Nozzle Pressure Nozzle Diameter
OVERSIZE CYLINDER SPECS
6.4 mm (1/4") 9.5 mm (3/8") 12.7 mm (1/2")
(new sleeve for oversize piston)
Cylinder bore (oversize) 62.45 – 62,46 mm – 2.4587 à 2.4591 kPa psi M ft M ft M ft
Cylinder bore (hone) 62.50 – 62,51 mm – 2.4606 à 2.4610 138 20 13.1 43 15.2 50 17.4 57
Surface Roughness 1 to 2 Micron – 39 to 78 Microinches 276 40 17.7 58 20.1 66 22.3 73
414 60 20.1 66 22.9 75 25.0 82
CLEARANCE DATA AND LIMITS 552 80 22.0 72 24.4 80 26.8 88
690 100 22.9 75 25.3 83 28.0 92
ROTAX
827 120 23.5 77 25.9 85 28.7 94
ENGINE 965 140 23.8 78 25.9 85 28.7 94
Spark plug type Bosch M4AC18 mm
Spark plug gap 0.41-0.51 mm / 0.016"-0.020"
Breaker points gap 0.35-0.45 mm / 0.014"-0.018" MAXIMUM PERFORMANCE
Ignition timing limits 2.54-4.01 mm / 0.100"-0.158" BTDC Pressure Discharge Flow
Ignition timing - nominal 2.54 mm / 0.100"BTDC
Magneto air gap 0.25-0.33 mm / 0.010"-0.013" kPa psi L/min IMP GPM US GPM
Condenser capacity 0.15-0.19 mF 345 50 337 74.1 89
Normal current for testing coil 1,0 amp. nominal / 2,0 amp. max. 517 75 314 69.1 83
Crankshaft axial clearance 0.2-0.3 mm / 0.0079"-0.0118" 690 100 295 65 78
Cylinder bore (hone) 62.50-62.51 mm 1034 150 246 54.1 65
Cylinder Surface Roughness 1-2 Micron / 39-70 microinches 1379 200 197 43.3 52
Piston dia. - nominal 61.94 mm/2.4386" 1724 250 144 31.6 38
Piston dia. - oversize 62.44 mm / 2.4583" 2069 300 95 20.8 25
Piston / cylinder clearance 0.06-0.08 mm / 0.0024"-0.0032" 2448 350 34 7.5 9
Wear limit 0.20 mm / 0.0079" 2620 380 0 0 0
Cylinder taper max. 0.08 mm / 0.0032"
Cylinder out of round max. 0.05 mm / 0.0020"
Piston ring end gap (new ring) 0.20-0.35 mm / 0.0079"-0.0138" METER HEAD OF WATER AND EQUIVALENT PRESSURE
Wear limit 1.00 mm / 0.03937"
Head of Pressure Head of Pressure Head of Pressure
Piston pin hole dia. (in piston) 18.001-18.005 mm / 0.7087"-0.7089"
Water Water Water
Piston pin dia. 17.997-18 mm / 0.7085"-0.7087"
Meters kPa Meters kPa Meters kPa
Crankshaft halves run-out 0.03 mm/0.0011"
1 9.8 11 107.8 21 205.8
Crankshaft bearing seat dia.
(on crankshaft coupling side) 20.002-20,011 mm / 0.7875"-0.7878" 2 19.6 12 117.6 22 215.6
Wear limit 20 mm / 0.7874" 3 29.4 13 127.4 23 225.4
(on crankshaft flywheel side) 25.002-25,011 mm / 0.9843"-0.9847" 4 39.2 14 137.2 24 235.2
Wear limit 25.000 mm / 0.9843" 5 49.0 15 147.0 25 245.0
Crankcase bearing seats dia. 6 59.8 16 156.8 26 254.8
(both sides) 51.95-51.96 mm / 2.0453"-2.0457" 7 68.6 17 166.6 27 264.6
Wear limit 51.98-51.99 mm / 2.0465"-2.0469" 8 78.4 18 176.4 28 274.4
Connection rod inside dia. 9 88.2 19 186.2 29 284.2
(for piston rim bearing) 21.997-22.005 mm / 0.8660"-0.8663" 10 98.0 20 196.0 30 294.0
Ring / piston groove clearance 0.04-0.11 mm / 0.0016"-0.0043" *** Performance will vary from location to location. Altitude dependant.
Wear limit 0.2 mm / 0.0079"
(measured on rectangular rings only)
11/2012

Stroke 61 mm / 2.40"
 www.wildfire-env.com • 1-800-426-5207 MARK-3® Service Manual 47

APPENDICES CONVERSION INSTRUCTIONS

B-7595, MARK-3 CONVERSION KIT

FROM POINTS TO CDI

Applies to MARK-3 units with the

points ignition

1. Take the 12-16 / 12-16S pump

end off.
2. Remove the fuel quick connect
from the frame.
3. Disconnect the fuel line from the
carburetor.
4. On the carburetor (R-1115), rotate FIG. 1: MARK-3, points style FIG. 2: MARK-3 with electronic ignition
the fuel strainer cover (R-1017) by
180 deg. (position A to position B)
(FIG. 3 #4).
5. Remove the frame from the
engine (FIG. 4).
6. Copy the whole pattern
(17/64” dia.) on the other leg,
at 2 5/8” from the original
holes (FIG. 5).

FIG. 3 #4 FIG. 4

FIG. 5

17
/64
2 5/8 (2 HOLES)
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APPENDICES CONVERSION INSTRUCTIONS (Continued)

7. Remove the spark plug cover

(R-413).

8. Remove the wire loom & cable

ties to uncover the cutout switch
wire. (If applicable).

9. Disconnect the cutout switch

wire from the blue female bullet
connector and cut the blue
connector off. (Color may vary)
(FIG. 6 #9).

10. Remove the clamp (R-409),

lock washer (R-521) and screw FIG. 6
(R-408) that hold the ignition
wire on the fan cowl.
(FIG. 6 #10)

11. Remove the fan cowl (R-411)

(FIG. 7 #11).

12. Remove the pulley - manual

starter rope (R-601)
(FIG. 7 #12).

13. Remove the gasket (R-653)

(FIG. 9 #13).

14. Remove the hex nut (R-302) that

locks the flywheel assembly in
place.
FIG. 7
15. Use the flywheel holding tool
(R-929), the puller magneto
(R-927) and an adjustable
wrench to remove the old
flywheel/magneto assembly
(R-667) (FIG. 8).

FIG. 8
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APPENDICES CONVERSION INSTRUCTIONS (Continued)

16. Remove the old Magneto from

the Flywheel and Fan assembly.

17. Install the new Magneto onto

the Flywheel and Fan assembly.
Use Lock-Tite Threadlocker
(Green).

18. Remove the old Armature Plate

Assembly (R-656) (FIG. 9 #18).

19. Cut the black female blade

connector on the green wire
from the new Armature Plate
assembly.
FIG. 9
20. Install the new Armature Plate
assembly. Pass the green wire
in the grommet of the existing
hole the engine’s crank case
(FIG. 10 # 20, FIG. 13 # 20).

Refer to installation instructions

of the electronic ignition on how
to adjust the timing.

21. Install the new Flywheel /

Magneto assembly and tighten
the Hex Nut (R-302) (FIG. 11).

Important:
Torque 390 – 400 inch lbs.
FIG. 10

FIG. 11
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APPENDICES CONVERSION INSTRUCTIONS (Continued)

22. Install the gasket (R-653)

(FIG. 12 #22).

23. Install the Pulley – Manual

Starter Rope (R-601)
(FIG. 7 #12).

24. Install the Fan Cowl (R-411)

onto the engine body, muffler
side first to have as much space
and play as possible
(FIG. 13 #24).

Do not install the top lock nut, FIG. 12

on the Air Filter’s side. It will be
used as a ground, at a later step.

25. Install a red female bullet

connector (PART-255) on the
green wire from the new
Armature plate (FIG. 14 #25).

26. Insert both the cut-out switch

wire and the small 3” long wire
in the red male bullet connector,
crimp them together with a
blue female bullet connector
(C-7010-12C). Insert a piece of
shrink tubing onto the wires
before crimping them together
(FIG. 14 #26).

FIG. 13

FIG. 14
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APPENDICES CONVERSION INSTRUCTIONS (Continued)

27. Install the frame back onto the

engine.

28. Install the fuel quick connect

(or brass fuel block on some
models) on the frame, using
the new holes you drilled in
step 6 (FIG. 15 #28).

29. Connect the fuel line on the Fuel

Strainer Cover (R-1017) you
rotated in step 4 (FIG. 3 #4).

30. Install the electronic ignition box

assembly (B-7592) in the old FIG. 15
holes of the fuel quick connect
on the frame (FIG. 16 #30).

Make sure to leave at least 1/16”

gap between the electronic
ignition box assembly (B-7592)
and the carburetor shroud
(R-790). It might be necessary
to sand the carburetor shroud
down to ensure a reasonable
gap. You may have to remove
the carburetor shroud to install
the electronic ignition box on
the frame.

31. Connect the on/off switch to the

cutout switch “Y” wire FIG. 16
(See step 26).

32. Connect the 3” long wire (from

step 26) to the black stop switch
wire coming out of the electric
ignition box. Connect both
wires together.

33. Connect the green armature

plate wire to the green STATOR
wire coming out of the electric
ignition box (FIG. 17 #33).

FIG. 17
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APPENDICES CONVERSION INSTRUCTIONS (Continued)

34. Connect the red (ground) wire

of the electronic ignition box
to the stud of the fan cowl
(FIG. 18 #34).

35. Install the rubber covered clamp

on the stud of the fan cowl,
then the missing lock nut from
step 24 (FIG. 18 #35).

36. Connect the spark plug ignition

cable from the electronic ignition
box to the spark plug.

37. Use the clamp (R-409), screw & FIG. 18

lock washer (R-408) to attach
the ignition cable on the fan
cowl of the MARK-3 just above
the cutout switch reset lever
(FIG. 19).

38. Install the 9” long wire loom

(FIG 20 #38A), insert all the
wires and connectors inside and
secure it with 3x 4” long cable
ties (FIG. 20 #38B).

FIG. 19

FIG. 20
11/2012
 www.wildfire-env.com • 1-800-426-5207 MARK-3® Service Manual 53

APPENDICES INSTALLATION INSTRUCTIONS

ELECTRONIC IGNITION UNIT

PROCEDURE: 2
1
• Remove old flywheel and armature
plate.

• Fit the new armature plate so that

the long holes are aligned
, 4
3
then turn it approx. 1 mm
counter-clockwise, then tighten
the 3 screws. 

• Turn crankshaft until the piston is

3.75 mm before top dead centre,
measuring through the spark plug
hole with a dial gauge. For the
final dynamic ignition timing
check make an ink mark on the
coupling buffer 12-17  as
well as on the flange – pump
mounting R-136. 
5
• Fit electronic box.  6
• Start engine and check ignition
timing with a stroboscopic lamp.
The 2 marks  previously
made must correspond at
3000 – 4000 r.p.m.

• If the 2 marks do not correspond,

remove flywheel and loosen the
3 screws  of the armature plate,
turn armature plate slightly in the
direction needed. Repeat the
procedure until the marks
correspond.

• Seal rubber grommet  with

Silastic.
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APPENDICES INFORMATION ON MECHANICAL CUT-OUT SWITCH FOR PREVIOUS

MARK-3 MODELS
Cutout Switch Adjustment (Static)
The cutout switch must be adjusted when installed in the fan cowl. This is necessary
because slight changes in the shape of the mounting plate occur when fastened in position
on the fan cowl.
Check that, with the air vane in the approximate centre of its travel, the spring attachment
holes "line up" with the pivot to form a a straight line (see FIG. 1). All brackets and pivot
should be perpendicular with the face of the plate.
Initial setting: A preliminary setting can be made by placing on the vane an object
sufficiently heavy to cause the vane to just leave the stop and start to move towards the
contacting position. A 2.5 oz (70 g) weight is used to approximate the setting during
FIG. 1 assembly. The final calibration must be made with the engine running.

Cutout Switch Adjustment (Dynamic)

1. Setup pump unit close to water supply. Use a 2 m to 3 m (6' to 10') suction hose with
footvalve attached. Connect a short length 2 m to 3 m (6' to 10') of discharge hose to
pump outlet. Attach a calibrated nozzle having a 12.7 mm (1/2") diameter orifice.
2. After starting and warming up engine thoroughly, increase to maximum recommended
power, then lift footvalve out of water supply. Engine will speed up then stop suddenly,
indicating the automatic cutout switch is functioning.
Should the switch not cutout after 1-2 seconds, while engine is running at increased
speed, close throttle and toggle switch immediately, otherwise serious engine damage
may result.
Assuming that cutout is functioning, then the speed setting of the switch should be checked
to make sure that it is not set too low or too high.
Use a reliable tachometer to check engine RPM.
3. Located in the upper centre of the outer surface of the fan housing, is a small socket
head adjustment screw. By using a 1/16" Allen key (tool R-909) and turning this screw
1/2 turn clockwise will increase the cutout speed setting approximately 150 RPM. A
1/2 turn counterclockwise will decrease speed setting approximately 150 RPM. After
each adjustment, recheck the actual speed at which cutout switch operates until proper
setting is obtained.
If a reliable tachometer is not available, then the cutout switch may be roughly calibrated
as follows:
Use a 3 mm (1/8") orifice tip screwed to nozzle. After warming up engine thoroughly,
increase to full throttle, then turn adjustment screw slowly counterclockwise until switch
cuts out and stops engine. Now turn screw one full turn clockwise and leave it in this
position.
The cutout switch will now operate automatically to stop engine should pump run out of
water, lose prime, etc. The switch will not interfere with normal operation of the unit and
will also allow the use of small nozzle tips as well as complete pump shut-off for short
periods of time.

Stop Switch Kit (R-633T)

20 R-665 Mach. screw 1 R-633-T
21 R-637 Flat washer 1
22 R-611 Lockwasher 1
23 C-7010-12 Stop switch assembly 1
24 C-7010-12C Connector 1 20 21 22 23 24 25
25 R-634* Cable stop switch 1
11/2012
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APPENDICES B-6289 DOS INSTRUCTION SHEET

2
3
1

The following items are included in the B-6289:

Ref. # Part # Description Qty

1 B-6289-2 DOS bracket 1
2 B-6289-5 Mach. screw, steel, plated 1
3 B-6289-1 DOS module 1
4 B-6289-6 Lock washer, steel, plated 4
5 B-6289-3 Mach. screw, steel, plated 2
6 B-6289-4 Mach. screw, steel, plated 2

Installation
To install the DOS, you will need the following tools:

• Flat screwdriver • Center punch • 10 mm wrench

• Phillips screwdriver • #30 drill bit • Cable ties
• Cutters • M4 x 0.7 tap & holder
• Pencil or marker • 11/32 wrench or socket
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APPENDICES B-6289 DOS INSTRUCTION SHEET (continued)

STEP 1
• Remove the ON/OFF
switch.
• Cut the upper cable tie
and partially remove the
split loom.

STEP 2
• Disconnect the splitter
wire (bullet connector
male) from the Stop
Switch wire coming from
the CDI module.

STEP 3
• Remove the "RESET"
decal.
• Remove the ignition cable
clamp.
11/2012
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APPENDICES

STEP 4
• Make a horizontal mark on
the bracket 1" from the top.
Place the bracket on the fan
cowl and line up the 1"
mark with the cylinder head
(as shown in the picture).
• Make sure that the bracket
lays flat on the side of the
fan cowl. Make sure that
the countersunk hole at the
center of the bracket is not
too close to the edge of the
fan cowl.
• Once installed, the DOS and
the bracket should clear the
spark plug cover and the
carburetor shroud.

STEP 5
• Mark the three holes (to be
drilled and tapped later).
• Center punch the three
holes.

STEP 6
• Loosen up the fan cowl and
rotate it as shown.
• Cut the cut-out switch wire
and remove the B-6288,
mechanical cut-out switch
including the reset lever.
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APPENDICES B-6289 DOS INSTRUCTION SHEET (continued)

STEP 7
• Drill the marked three
holes with a #30 (.1285")
drill bit.
• Tap the three holes
M4 x 0.7.

STEP 8
• Relocate the fan cowl at
its proper
location and tighten nut.
• Install the bracket using
three screws and two
tooth lock washers.
• Install the DOS using two
screws and two tooth lock
washers. Make sure the
DOS is strongly mounted
on the bracket to ensure
proper ground contact.

STEP 9
• Connect the DOS wire
to the stop switch wire
coming from the CDI
module.
• Secure the wiring.
• Re-install the split loom
around the cables and
secure with a cable tie.
11/2012
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APPENDICES OPERATION

Starting the engine:

• Before starting the engine, it
is recommended to pull the
starter rope and crank over
the engine a couple of times
in order to charge up the
DOS. This will facilitate the
starting. The LED will light
up while the DOS is being
charged.
• Start the engine as directed
in the MK-3 Instruction &
Service manual. (Note that
there is no ON switch.)
Stopping the engine:
• To stop the engine, press the
OFF button until the engine
shuts down.
Overspeed condition:
• If the engine starts to
overspeed, the DOS will
automatically shut down
the engine.
• Always make sure that
the cause of the overspeed
condition has been
identified and corrected
before attempting to
restart engine.
• When attempting to restart
the engine (after overspeed
condition or pressing OFF
button), wait 10 seconds
from the time the engine
shut down; this will enable
the DOS to reset itself.
Failure to wait the
prescribed duration of time
will make it difficult to
impossible to start the
engine. It may also lead to
a flooding condition.
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APPENDICES IGNITION TIMING TOOL R-954-14

Instructions
To check ignition timing,
proceed as follows:
1. Inspect breaker points. Clean
or replace if necessary, then
reset gap. Refer to “Servicing
Magneto” in the MARK-3
Service Manual.
2. Remove spark plug.
3. Slowly screw timing gauge
(R-954-14) into spark plug open-
ing, while rocking crankshaft
back and forth until piston just
touches bottom of gauge. Piston
is then at top dead centre. Cylinder head
4. Leave timing gauge in this
position.
5. Rotate crankshaft approximately
90˚ counterclockwise.
6. Insert 0.0015” (0.04 mm) feeler
gauge between breaker points.
7. Mark cylinder head fin with a
small mark aligned with the
zero “0” on the gauge. Screw
timing gauge in to 0.147” R-954-14
Ignition timing gauge
(3.734 mm), or almost three
complete revolutions (0.050”
per revolution).
8. Slowly rotate crankshaft clock-
wise until piston comes to rest
against gauge plunger.
9. Timing is correct if the 0.0015”
(0.04 mm) feeler gauge slips
easily from between the points
as the piston touches the
plunger. If timing is incorrect, it
can be corrected by rotating the
armature plate assembly clock-
wise to retard, counterclockwise
to advance the timing.
10.Reinstall flywheel and set air
gap between the flywheel
magnets and ignition coil to
0.010” (0.254 mm).
Note: Do not exceed recommended
“gap limits” when setting breaker
points.
11/2012
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PARTS INDEX
PART # DESCRIPTION PAGE PART # DESCRIPTION PAGE

12-2C Shaft - riveted assembly 42 A-1888 Puller - suction nozzle 42, 43

12-2D Shaft sub-assembly of 7 items 42 A-1890 Pressing pin - shaft removal 42, 43
12-2E Shaft sub-assembly of 4 items 42 A-2356 Maintenance tools for pump 43
12-3 Retaining ring for bearing 42 A-2388 Pump test kit 17
12-6 Distributor 42 A-2389 Pump test kit box 17
12-7 Impeller 42 A-2390 Pressure gauge adaptor, 38 mm (1 1/2”) 17
12-8 Pump body 41 A-2390A Shut-off valve 17
12-9 Distributor 42 A-2391 Rubber hose assembly with A-2391B 17
12-10 Cap for priming port 41 A-2391B Adaptor 17
12-11 Impeller 42 A-2392 Pressure gauge, 0-2800 kPa (0-400 psi) 17
12-12A Suction nozzle (includes 12-40) 41 A-2395 Brass calibrated nozzle tip set 17
12-13 Nose for shaft 41 A-2688 Thread protector 51 mm (2”) 41
12-17 Coupling - buffer 21, 42 A-2924 Reset rod 29
12-25 Mach. screw flat Phillips, stainless 42 A-2926 Cable 29
12-26 O-ring 42 A-3023 Carburetor adjusting tool 19
12-27 O-ring 41, 42 A-4005 Mounting pad 43
12-28NS Mechanical rotary seal 41 A-4027 Pin - index 28
12-29 Grease fitting 41 A-4028 Spring 28
12-38 Lockwasher 29, 30, 35, 37, 41 A-4030 Throttle decal (english) 28
12-39 Mach. lock screw, Fillester, stainless 41 A-4097 Protector - shaft 43
12-40 Bushing bearing, bronze 41 A-4329 Pressing sleeve - rotary seal assembly 42, 43
12-42 Mach. lock screw, Fillester, stainless 41 A-4452 Link for lever side 15
12-43 Gasket, 38 mm (1 1/2”) 41 A-4453 Eye-bolt 15
12-48 Double row ball bearing 42 A-4454 Clevis pin for eye-bolt side 15
12-48S Sealed double row ball bearing 42 A-4455 Clevis pin for lever side 15
12-49 Lockwasher, stainless 42 A-4456 Knob for tension adjustment 15
12-50 Lock nut, stainless 42 A-4460 Lever 15
12-73 Plug, brass 42 A-5297 Support tool 42, 43
12-79 Lockwasher, star type 28 A-5536 Protective cap, discharge 41
12-87 Extension for grease fitting 41 A-5537 Protective cap, suction 41
12-401B-NS Hose-fuel supply with priming bulb 43 A-5538 Retainer for priming cap 41
212-170P Clamp assembly 15 A-6510 Decal for electronic ignition 20
271-346 Screwdriver - standard 35 A-6149P Mounting leg 37, 43
271-488 Bag - tool roll 19 A-6179 Ring - rubber 43
271-923 Wrench - adjustable 203 mm (8") 19 A-7486 Dust cap male connector 43
271-927 Screwdriver - Phillips No 1 35 A-7487 Dust cap fem. connector 43
A-1884 Pressing sleeve - distributor assembly 42, 43 A-7589 Mounting block, electronic ignition 20
A-1886 Pressing pin - distributor removal 42, 43 A-7644 Seal puller for 12-28NS 41, 43
A-1887 Guide - shaft aligning, body 42, 43 B-2428-6 Hex lock nut 29
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PARTS INDEX
PART # DESCRIPTION PAGE PART # DESCRIPTION PAGE

B-2920-6 Flat slotted bolt 29 R-119 Lockwasher 28, 29, 37, 44

B-2920-23 Grommet 29 R-120 Hex nut 28, 37
B-4024 Quadrant for throttle lever 28 R-123 Oil seal 0.788" 37, 39
B-4036-12 Mach. screw hex socket 28 R-130 Stud - mounting leg 37
B-4457 Clamp - bottom half 15 R-132 Mach. screw, steel plated 37
B-4461 Clamp - top half 15 R-133 Gasket for crankcase 37, 39
B-5562-18 Plastic coated clamp 20 R-136 Flange - pump mounting 21, 37
B-6288 Cutout switch assembly 18, 29, 46, 49 R-144 Shield - dust 37
B-6289 Digital Overspeed Switch (DOS) 18, 47-51 R-146 Mach.screw 35, 37
B-7595 MARK-3 conversion kit (Point to CDI) 20 R-149 Lockwasher 28
C-1933 Calibrated nozzle 12,7 mm (1/2”) 17 R-150 Hex lock nut 14, 28, 29, 44
C-4506-3 Bumper - rubber 43 R-151 Flat washer 29, 44
C-5200-5 Washer - rubber 43 R-152 Crankcase halves set 37
C-5200-6 Flat washer 43 R-206 Flat washer 37
C-5200-7R Spacer - rubber 43 R-229 Muffler 44
C-5200-8 Hex bolt 43 R-233 Cylinder head -18 mm 23, 28
C-5200-12 Hex bolt 43 R-235 Gasket - cylinder flange 28, 39
C-5200N Mounting frame assembly 43 R-236 Stud - cylinder mounting 37
C-5201 Frame 43 R-237 Gasket - muffler 28, 44
C-5370-11 Flat washer 37, 44 R-238 Gasket - cylinder head 23, 28, 39
C-6650-14 Hex lock nut 43 R-257 Cylinder 28
C-7010-12 Stop switch assembly 14 R-270 Cast iron sleeve 28
C-7010-12C Connector 14, 36 R-271 Electronic Ignition conversion kit 20
D-2902-9 Grommet 20 R-301 Lockwasher 38
D-5269-7 Flat washer 43 R-302 Hex nut (coupling side) 38
FA-552Q Fuel air transport tank 43 R-303 Hex nut (flywheel side) 38
FAST-18 Bolt, hex, steel plated 20 R-305 Key 38
FAST-20 Bolt, hex, steel plated 20 R-306 Shim 0.006" (coupling side) 38
FAST-510 Flat washer, steel plated 20 R-307 Shim 0.008" (coupling side) 38, 39
MK-138 Gasket 51 mm (2") 40 R-308 Shim 0.012" (coupling side) 38, 39
MTR-1000 Hours meter with RPM 28 R-309 Shim 0.016" (coupling side) 38, 39
PART-37 Female disconnect terminal, insulated 20 R-310 Shim 0.020" (coupling side) 38, 39
R-103 Dowel tube 37 R-311 Shim 0.031" (coupling side) 38, 39
R-105 Mach.screw 37 R-312 Shim 0.040" (coupling side) 38, 39
R-111 Lockwasher 43 R-315 Collar coupling 38
R-113 Gasket, metal 37 R-321 Serrated lockwasher (old style engine) 38, 39
R-115 Stud 29 R-324 Needle bearing 38, 39
R-116 Hex nut 35 R-324M Crankshaft / conn rod (half coupling side) 38
R-117 Stud 28, 37 R-328 Gudgeon pin 38
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PARTS INDEX
PART # DESCRIPTION PAGE PART # DESCRIPTION PAGE

R-329 Circlip 38 R-526 Washer - friction 30

R-331 Piston ring, 0.078" 38 R-528 Pawl assembly 30
R-331-0 Oversized piston ring 0.078" 38, 39 R-529 Rewind starter 30
R-331-0-1 Oversized L-type piston ring 38, 39 R-530 Housing - starter 30
R-331-1 L-type piston ring 38 R-531 Retainer - spring 30
R-332 Piston with rings 38 R-532 Cover 30
R-332-0 Oversized piston (includes rings) 38, 39 R-533 Guide - starter rope 30
R-333 Ball bearing 0.788" ID 35, 38, 39 R-544 Buffer - rubber 30
R-334 Spacer 38, 39 R-601 Pulley - manual starter rope 35
R-341 Crankshaft / conn. rod sub-assembly 38 R-602 Stud 35
R-341M Crankshaft / conn. rod (half flywheel side) 38 R-603 Fan 35
R-342 Oil seal 0.983" 37, 38, 39 R-611 Lockwasher 36
R-343 Ball bearing 0.983" ID 38, 39 R-628 Cable condenser 36
R-344 Shim 0.004" (flywheel side) 38, 39 R-629 Spark plug 18 mm 14, 20, 36
R-345 Shim 0.012" (flywheel side) 38, 39 R-630 Cable - spark plug 36
R-346 Shim 0.020" (flywheel side) 38, 39 R-633-T Stop switch kit 36
R-347 Shim 0.039" (flywheel side) 38, 39 R-634 Cable stop switch 36
R-348 Crankshaft / conn. rod assembly kit 38 R-636 Grommet 36
R-402 Stud 28, 29 R-637 Flat washer 36
R-408 Mach. screw 29 R-638 Mach. screw 36
R-409 Clamp - ignition cable 29 R-650 Protector - spark plug 14, 20, 36
R-411P Fan cowl with studs 29 R-653 Gasket 35
R-413 Cover for spark plug 29 R-654 Cap 36
R-414 Mach. screw hex cap 29 R-655 Mach. screw 36
R-418 Shield - fan 29 R-656 Armature plate complete 36
R-501 Handle - starter rope 30 R-661 Coil 36
R-502 Rope - starter 30 R-662 Condenser 36
R-504 Aluminium sheave 30 R-664 Point with cable condenser 36
R-505 Lock pin 30 R-665 Mach. screw 36
R-506 Spring - rewind 30 R-667N-E Flywheel/magneto assembly 35
R-509 Plug - rubber 30 R-706 Body quick-connect male 43
R-510 Flat "D" washer 30 R-709 Elbow 43
R-516 Spring - friction 30 R-712 Handle quick connect, female 43
R-517 Flat washer 30 R-732 Connector SAE male 43
R-518 Circlip 30 R-774 Mach. screw 28
R-521 Lockwasher 29, 30, 35, 37 R-790 Carburetor shroud with decal 28
R-522 Mach. screw hex cap 30 R-791 Lockwasher 28, 35
R-523 Lockwasher 30 R-792 Throttle control assembly 28
R-524 Mach. screw 30 R-793 Mach. screw hex cap, Nylock 28
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PARTS INDEX
PART # DESCRIPTION PAGE PART # DESCRIPTION PAGE

R-794 Cover for air filter 28 R-1014 Mach. screw with lockwasher 25
R-798 Fuel line, plastic 43 R-1015 Fuel strainer screen 25
R-799 Bracket 28, 37 R-1016 Fuel strainer cover gasket 25
R-900 Maintenance tool kit for pump 19 R-1017 Fuel strainer cover 25
R-901 Screwdriver, 102 mm (4") sq. handle 19 R-1018 Mach. screw 25
R-902 Screwdriver, 51 mm (2") 19 R-1019 Idle mixture screw 25
R-903 Feeler gauge - spark plug & breaker point 19 R-1020 Mixture screw spring 25
R-904 Wrench - spark plug 19 R-1021 Flat washer, brass 25
R-904L Wrench for lock nut/spark plug 41, 43 R-1022 Idle speed screw O-ring 25
R-905 Handle - rod 19 R-1023 Idle speed screw 25
R-906M Wrench - box and open end 10 mm 19 R-1024 Idle speed screw spring 25
R-908 Wrench - open end 5 & 8 mm (ignition) 19 R-1025N Inlet control lever 25
R-909 Key - Alien 2.4 mm (3/32") 18, 35 R-1029 Inlet tension spring 25
R-910 Wrench - open end 1/2” & 9/16” 19 R-1030 High speed mixture screw 25
R-911M Wrench - box and open end 13 mm 19 R-1034 Nozzle check valve 25
R-926 Socket wrench 14 mm (9/16”) 35 R-1035 Throttle shaft and lever 25
R-927 Puller - magneto 35, 37 R-1036 Throttle shaft clip 25
R-928 Cap - shaft protector 35, 37, 38 R-1037 Lockwasher 25
R-929 Flywheel holding tool 35, 37 R-1038 Mach. screw 25
R-930 Puller - crankshaft bearing R-313 35 R-1039 Throttle shaft return spring 25
R-932 Puller - collar coupling 35, 37 R-1040 Throttle shutter 25
R-933 Oil seal - pressing tool 35, 38, 39 R-1041 Mach. screw with lockwasher 25
R-938 Puller - crankshaft bearing Ft-333 35, 38 R-1044 Lock plate 28
R-952 Service toot kit 35 R-1045 Body 25
R-953 Crankshaft jack 35, 39 R-1046N Inlet needle and seat 25
R-954-14 Gauge - timing 35, 59 R-1047 Inlet seat gasket 25
R-955 Air filter element - foam & screen 28 R-1050 Repair parts kit 25
R-1001 Body channel welch plug 25 R-1101 Throttle link lever assembly 25
R-1002 Choke friction pin 25 R-1102 Link for throttle 28
R-1003 Choke friction spring 25 R-1107 Throttle lever sub-assembly 28
R-1004 Choke shaft and lever 25 R-1110 Hex nut 25
R-1005 Choke shutter 25 R-1111 Bolt 25
R-1008 Diaphragm gasket 25 R-1113 Gasket - carburetor 25, 28
R-1009 Diaphragm 25 R-1114 Quick connect fuel line assy 43
R-1010 Diaphragm cover 25 R-1115 Carburetor (45 parts) 25
R-1011 Fuel pump gasket 25 RA-108 Mach. screw hex cap 37, 44
R-1012 Fuel pump diaphragm 25 TY-1811 Hex nut 29
R-1013 Fuel pump body 25
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NOTES
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NOTES

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WARRANTY
A. Warranty on Products Distributed by Wildfire
Wildfire makes no warranty, express or implied, with respect to any product distributed by it and manufactured by third-party manufacturers. You,
the purchaser, can only rely upon such warranties, if any, that are made by their respective manufacturers and subject the limitations that may be
contained in such warranties according to the respective terms thereof. Wildfire hereby assigns, as applicable, any such manufacturer warranty to
you as the purchaser, if assignable. However, Wildfire disclaims all other warranties or conditions for items whether express, oral, implied or
otherwise, as to any matter whatsoever, including but not limited to, implied warranties or conditions of merchantable quality or fitness for a
particular purpose and those arising by statute or otherwise in law or form a course of dealing usage of trade.
B. Warranty on Products Manufactured by or for Wildfire
Wildfire offers a limited warranty as described fully below. Among other things, it also specifically disclaims liability for:
• Failure of the product if it is used for other than its intended purpose.
• Changes or modifications not expressly approved by Wildfire.
• Unreasonable use, supplemental damage, or damage to the product not resulting from defects in material or workmanship.
• Any personal injury, damages of any kind resulting from misuse, improper installation, negligence, repair or alteration of the product.
No Consequential Damages
Some states and provinces do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations may not apply
to you. This statutory warranty gives you specific legal rights, and you may have other rights, which vary from state to state or province to province.
Wildfire offers a limited guarantee of all products manufactured by Wildfire to be free of defects in material and/or workmanship for a period of
one (1) year from date of invoice subject to use of such products strictly according to instructions. Any product manufactured by or for us believed
by you to contain a defect must be returned to Wildfire for examination and evaluation. You are responsible for payment of transportation charges.
If after inspection by us or an expert appointed by us the product is in fact found to be defective, Wildfire will repair or replace the defective
product and reimburse the original buyer for transportation charges to and from our warehouse.
Limitation of Liability
THE WARRANTY SPECIFIED HEREIN IS LIEU OF ANY AND ALL OTHER WARRANTIES, EXPRESSED, OR IMPLIED.
Wildfire hereby expressly disclaims any express or implied warranties of merchantability or of fitness for any particular purpose.
Wildfire’s liability on any claim of any kind, including negligence, for any damage or loss including but not limited to personal injury or
consequential damage arising out of, connected with or resulting from this contract, or from the manufacture, lease, sales, delivery, resale, return,
repair, maintenance, handling or use of any product covered by or furnished under this sale, shall in no case exceed the purchase price. Wildfire shall
not be liable for any penalty or for any special, indirect or consequential damages, including, but not limited to, any economic loss, loss of revenue
or loss of opportunity.
The foregoing warranty is in lieu of all other warranties, express or implied, including but not limited to, any implied warranties of merchantability
or fitness for a particular purpose. Your exclusive remedy with respect to any and all losses or damages resulting from any cause whatsoever, including
our negligence, shall be repair or replacement as specified above. We shall in no event be liable for any consequential or incidental damages of any
nature, including without limitation, damages for personal injury or damages to property, and however occasioned, whether alleged as resulting
from breach of warranty or contract by us or our negligence or otherwise.
11/2012
 Tech-notes, part lists and other documents
can be found on our web site at
www.wildfire-env.com

Wildfire Environmental USA Inc.

16311 NE Cameron BIvd 950 Riverside Parkway, Suite 50
Portland, OR West Sacramento, CA
USA 97230 USA 95605
Tel.: (800) 426·5207 Tel.: (800) 426-5207
(503) 257-7900 (916) 372-9004
Fax: (503) 257-7979 Fax: (916) 372-9006

Wildfire Environmental Inc.

1100, rue Norman street, Suite 200 7965 Venture Place, Unit #3 17426 - 106A Avenue
Lachine, QC Chilliwack, BC Edmonton, AB
Canada H8S 1A6 Canada V2R 0K2 Canada T5S 1E6
Tel.: (800) 426-5207 Tel.: (800) 426-5207 Tel.: (800) 426-5207
(514) 637-5572 (604) 392-2240 (780) 484-3705
Fax: (514) 637-3985 Fax: (604) 392-2241 Fax: (780) 484-5115
E-mail: [email protected]

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