ASPERA motors MECHANIC’S HANDBOOK 2 STROKE ENGINES DIREZION! E STABILIMENTO 10135 TORINO VIA DELLE CACCE 99 34.2002 % ASPERA MOTORS TORINO SEDE SOCIALE: 10142 TORINO VIA ASIAGO 5 — SERVIZIO RICAMB/ 10142 TORINO VIA ASIAGO 5 72.13.03curren STARTERS 2-1 GENERAL The starters fitted to ASPERA MOTORS engines can be divided into three basic groups, according to the starter hub driving system employed, ‘1st Group ("Eaton type rope rewind starter). (or Ezee start). This type Is fitted to LAV-H-TA-TH-VA- AH51 St engines, and is characterized by a dog which meshes with an internally toothed starter hub when the rope is pulled. This type is fitted to AH47-AHS8-AH81 and AV4T engines, and is characterized by a pair of ‘shoes which engage with an Internally non-ser- rated hub, activated when the rope is pulled. 3rd Group (“Eaton type Impulse starter). This type may be fitted as an alternative to the first group types on all engines. The method of operation is by preloading a spring by means of fa handle, The spring is then released by oper- ating @ trip lever, the resultant inertia of this acting on the hub then turns the engines. 2-2 1st GROUP STARTERS The rope rewind "Eaton" type has been adopted for 3 models (see fig. 22/1) Fig. 22/1 Eaton Rewind type The three are:— Type No. 4201001 {earlier type no longer fitted). Type No. 4210020 (more recent type no longer fitted). Type "C". No. 4210021 (type now fitted) NOTE: In case of replacement of the starter only, It Is recommended that a starter of the same type Is fitted. To fit starter type "8" on an engine pre- viously equipped with starter type A”, itis also necessary to replace the hub ‘and screen. To fit starter type "C on an engine pre- viously equipped with a starter type "A” or "B™, It Is necessary to replace hub ‘and screen flywheel and associated nut and washer. 2-3 2nd GROUP STARTERS The second group consists of two models whose features are very similar (see fig. 2-3/1). Fig. 23/1 “Falbanks: Morse Thxy are motnted: Type “A” on AHA7 and AHSS engines (No, 4210517 clockwise, No. 4210518 counterclockwise). ‘Type "B" on AHS! and AV47 engines (No. 4210526 clockwise, No. 4210527 counterclockwise)2-4 3rd GROUP STARTERS This group consists of two models (see fig. 24/1). Type "A" economy No, 4210510 Type "B" deluxe No. 4210015 @ ; £2 CE Fig. 24/1 Impule type. Fig. 25/2. Operation 2 (A). 1) Pull starter rope (12) about half way, and 2-5 OPERATIONS ON STARTER prevent recoil by firmly holding pulley (9) TYPE "B" OF FIRST GROUP 2) Tie a knot on rope A (see fig. 2.5/2) to (No. 4210020) Prevent recolling and remove handle (13 2 ‘and 14) by loosening the knot fastening To disassemble starter, proceed as follows: iheslidierd eocheroees (Fig. 25/1 refers). 3) Loosen the knot previously tied on rope and let the spring unwind by slowly re- ing the pulley, B ~ Unscrew centre screw (1) and remove brake and dog assembly (parts 2-3-4567). ig. 25/1 exploded view type B - It group. ‘A~ Release tension of spring (10) to avoid ac- cident during disassembly as follows: Fie 25/3. Starter Bese PingC- Carefully remove pulley making sure that main spring does not escape from its housing. The starter will then be completely disas- sembled. Before reassembling starter It Is Important: 1) To check brake (6) for tight fit about retainer hhub body (4). If brake is a loose fit, it should be replaced (see fig. 25/3). Fig. 25/4 2) Check main spring for troublefree operation. If the main spring is damaged, remove by sharply striking starter box (11) on bench, keeping box feet downward to avoid injury by the spring suddenly being released from Its housing. To refit 2 new spring in its housing, Fig. 25/5. Locating the sprog. use a genuine spare part supplied in the spe- ial keeper (see fig. 2-5/4). Rest spring con- tainer on inner surface of starter housing, locate outer hook of spring "A" In the asso- lated notch in the housing (see fig. 25/5), and press spring fully home (see fig. 25/6) Lubricate spring well with soft of Fig. 2.5/6 Spring In poston. To reassemble stater. A) Re-seat pulley after having woundion the rope leaving the end through the notch provided ‘on the pulley (see fig. 28/7). Insert pulley Into the container, making sure that the spring locates in the notch provided. Fig. 25/7 Fig the pulley. 'B) Reassemble brake (6) and washers (3 and 7), on retainer hub, greasing liberally. ©) Refit dog in its housing ii the pulley. D) Connect return spring (5) to lug on retainer hub (4), then, tensioning the spring, connect ‘the other end to the post on the pulley while simultaneously seating retainer hub (see fig. 2-5/8), and secure with screw and washer (1 and 2)Fig: 25] tocting vourn pring E) Tired the rope through the guide hole and sit the handle. F) Pull the rope and check that the pulley winds five complete turns If not, the pulley may be further wound by fitting the rope in th. notch In the pulley and then turning the pulley ‘the necessary extra amount by hand, @s in fig. 25/9. Then ascertain that dog protrudes from its slot by slightly pulling the rope. Next check that the rope can be pulled to its full extend and that it completely rewinds, and holds the handle firmly to the starter. 2-4 NOTE: NoTE: By observing the following procedure, a broken or damaged rope can be replaced without dismantling the starter. Completely wind up the pulley (if the rope is not broken, it is possible to pull the rope to the end of its stroke). Hold the pulley in this position, cut and with draw the old rope and insert a new one, still keeping the pulley locked in this position. Should the main spring have left its hous- Ing during disassembly operations, it must be rewound and replaced in its housing. Fig. 25/10 Refiting springBegin from the outside, securing the spring ‘on the outer side of housing in starter box (see fig. 25/10), and then wind up ‘counterclockwise working towards the centre. This operation can be f winding the spring into one of keeper rings supplied with each new sprig. Then refit as per a new spring. OPERATIONS ON STARTER TYPE "A" OF 1st GROUP (No. 4201001). This starter wes produced previous to No. 4210020 (type "B"), and its operation is almost the same as that of the latter. For operations on this unit, refer to the above instructions and the exploded view (see fig. 2-6/1). Fig. 2.4/1 tapladed view type A = It grou 2-7 OPERATIONS ON STARTER TYPE "C" OF 1st GROUP (No. 4210021) In the event of starter failure, remove the unit from the engine and check the following items 1) That dog (A) (fig. 2-7/1) protrudes when the rope is slowly pulled. If the rope cannot be pulled, check the retainer hub "B” locking screw for correct tightening torque, which should he - kgm. 05-06 (45/55 inch. Ibs.). Fig. 27/1 Checking Dog 2) If, after correct screw tensioning "B”, the dog does not function, disassemble the starter as follows, referring to exploded view shown in fig. 2-7/2. To disassemble starter. a) Release spring. With this starter it is more expedient to slide the rope off the pulley by loosening the knot (see fig. 2-7/3). To do this, pull the rope completely and locking the pulley, slide the rope into the associated slot. Then slightly release pulley while exerting a light pressure with the thumb upon pulley. b) Remove centre locking screw. ©) Remove retainer hub, brake spring and dog Fig 27/2 kxpleded view type C+ 14 prove.Fg. 2.7/3 Removing rope 4) Remove dog return spring "B ’, bearing in ‘mind its position for correct replacement (see fig. 2-7/8) 2} Remove pulley and spring container assembly. A) Once the damaged parts have been replaced, lubricate spring container with soft grease (see fig. 27/4) and proceed with reassembly. Fg. 2.7/4 Spring and contane. To reassemble starter. ) Accuratsiy position spring container on pulley (see fig 27/5). 2-6 'b} Reposition the pulley assembly into container, lubricating shaft and bushing of plastic pulley. Fig. 2.7/5 8 Spring dicengegement ©) Refit retainer spring, place dog and brake spring in position (see fig. 2-7/6). 4) Accurately position retainer hub and secure with the screw, Fig. 27/6 og and brake spring post €} Prestension soring five turns and keep plastic pulley locked with the thumb. f] Thread rope in and re-tie the knot, thereby securing the rope to the pulley. After reassembling starter: Always make sure that by pulling the rope slightly, the starter dog operated and by pulling the rope completely, a full stroke is obtained and when released, fully recoils, and that the handle is held firmly to the starter.2-8 OPERATION ON STARTERS TYPE "A” AND "B” OF 2nd GROUP "Falrbanks Morse" starters are also of the re- wind type and the main apring-pulley system Is similar to that of the starters already dealt with. The basic difference between these starters and those of the first group, as can be seen from the exploded view fig. 2-8/1, Is solely In the me- thod of securing the assembly to the hub. To disassemble starter. 1) Move starting lever to start position in order to release spring tension. 2) Remove starter from engine. 26) @® a) @) ® le i Fig. 28/1 taploded ny type A and B+ And group. For repairs to this type of sterter, refer to the ‘exploded view, and proceed as follows:— A~ Ascertain that the shoes are so fitted that sharp edges engage the hub. B ~ Should edges be worn, rotate friction shoe. G~ Should slipping occur, check that mating faces of the two fibre washers are not fouled with grease. D~ Direction of rotation of starter can be ri versed by inverting main spring, friction shoes assembly and the reverse winding of the rope on the pulley. 2-9 UPERATIONS ON STARTER TYPE "B" OF 3rd GROUP (No. 4210015) For repairs to this type of starter, dismantle as follows, referring to exploded view 2.9/1:— )@ Q 6666 q arn { Fig. 2.9/1 Exploded view type B= 2rd. grovp, 3) Extract centering shaft (1) 4) Extract retainer hub (3) loosening clamping screw (2) (leftthand thread). Check brake (4) It should firmly grip retainer hub. If brake Is not securely fitted, starter dogs (6) do not Separate. In case of looseness, fit a new shaft. 5) Remove brake washer (5) and starter dog (6) 6) Remove cover assembly (24), and keeping the legs downwards, extract container as- sembly with spring (9) by tapping.7) Remove locking washer (12) (it should al» ways be replaced by @ new one}, toothed crown (11) and spring cover (10). Check spring for fouling, clean if necessary. If broken of damaged or does not engage starter hub, it should be renewed. Spring and con- tainer are replaced only as an assembly. 8) Remove screw (13), engaging washer (14), spring washer (16) and locking washer (15) from ratchet (17), and check tension of spring washer. If it Is fatigued, replace. 9) Check extent of wear of locking paw! (22) and ratchet teeth. Check tension of spring (23). It should hold ratched firmly against gear. 10) Remove friction spring (26) from handle (28) ‘and ensure that there is sufficient tension. Clean and wipe dry. 00 NOT LUBRICATE. To reassemble starter. Accurately re-position spring into handle. 2 Coat ratchet (17) with soft grease. With fone hand keep lock dog (22) against return spring (23) and re-position ratchet (17). Lock og should be kept stationary between teeth of rotating gear. 3) Re-position handle, spring washer, lockwasher ‘and screw. 4) Place washer (8) on hub. Install hub (7) onto cover and spring assembly (9). Install cover (10) and gear (11). Fit @ new retainer ring (12) to secure the assembly. 5) Push cover and spring assembly in its seat Make sufe that cover teeth mesh with ratchet teeth. 6 Reassemble brake and washer on retainer hhub (ascertain thet brake Is fixed securely on hub). Fit starter dogs and tighten locking screw. 1 Insert one end of centering pin (1) into centre of screw (2) Resfit starter with other end of centering pin Into hole drilled in the centre of crankshaft. 2-8 9) Insert the four screws into the cover holes, screw the screws half way into air shroud holes and push starter completely home, 10) Tighten screws. NOTE: Centering pin must be used with these starters, in order to obtain proper align- ‘ment of hub and screen. 2-10 OPERATIONS ON STARTER TYPE "A" OF 3rd GROUP (No. 4210510) This starter differs from the foregoing by a num- ber of features and is of much simpler design. ‘The main difference being the fact that the spring directly wound instead of by means of the re- duction geer (see fig. 240/1) Fig. 210/1 tapladed view ype A + 3rd grovp.2-11 SIDE MOUNTED STARTER ‘The side mounted starter has been develloped for ‘The starter operates the engines by engaging a use on machine where the engine is mounted in gear on the teeth on the underside of flywheel 2 low position as in fig. 241/1 fig. 2-11/2. When the engine starts. the flywheel speed disengages the starter gear. Fig. 2411/2 Engg sistem. f Fig. 2.11/1 Side mount starter. Re iywhee! Gene; 8 = Polley Gnu. 2-12 REMOVING (Fig. 2-12/1) Remove the pulley as follows:— Fig 2412/1 expla view.— Release main spring (5) by separating the handle and sliding the rope (12) out of the rope clip (18) see fig, 2-12/2 — Remove rope clip and replace if necessary. — Remove the two screws (1) and spring co- ver (2) The spring may be replaced at this point wi thout further dissasembly. — Remove old spring (5) end place new spring complete with keeper in position and push spring into place in the container (fig. 2-12/3) — For further dissasembly remove central fixing screw (3) and remove pulley assy (see fig. 2412/4) Fig. 212/4 Ausy Geartolley — Remove brake spring (10) and circlip (9). washer (8), and separate gear (7) from pul- ley (6). If necessary replace rope (12) re- ferring to fig. 2412/5. Fig. 212/5 Remove rope from pulley une knot (A), — Untie knot “A” and remove rope from handle (14) and pulley (6). — Fit a new rope of the same dimentions and retie knot, — Check all parts before reassembly. 2-13 REASSEMBLING Refit gear (7) on pulley (6) and secure by the spring clip and washer. NOTE: Wind the rope onto the pulley and fit the gear and pulley assy onto the bracket pin (11) fig. 2419/2. Secure the assy with screw (3) fig. 2-13/1. Fit new brake spring (10) in its seat (fig. 243/2), being careful to fit the side extention of the spring on its seat Refit the spring cover and secure with its two screws.Fig, 2.13/1 Starter suey sing ere (A) Pre-tention the spring by completely winding the rope onto the pulley in the direction of the arrow (fig. 2-13/3). When the rope is fully wound give the pulley one more complete turn to obtain correct spring ten- sslon and fit the rope container (see fig. 3-13/4) ig. 2413/2 Beakat pin lection, NOTE: ‘The main spring and spindle only must be greased. Do not grease the brake spring etc. In order to prevent the acumulation of dust, Fig 2413/3 Pretenion. Fig. 213/4. Spring tena 2-14 FAULT CHECKING A) When rope does not recoil check the spring stop, if this does not slide, tighten the centre screw (3). If the centre pin Is loos cket (11). replace the bra- 8B) When the gear does not engage, check: the distance between the gear and flywheet teeth should not be greater than 1/16" (see fig. 2-14/1), To adjust, slacken clamp screws and adjust to correct distance, retighten screw: if the brake spring is @ loose fit, replace and check the breaking action on the gear. ©) Pull the starter rope and check that the rope container Is not loose and that the rope is of the correct length and diameter (5/32") 15% the Fig. 2.4/1 Distance between the Gear snd Flywheel seth 2-15 REFITTING TO ENGINE The distance between the gear teeth and the flywheel teeth must be 1/16”; the clamp bracket ‘mounting holes are elongated to provide this adjustment.2-16 STARTER FOR ZH ENGINES General ZH engines starters are similar to the first group rewind starter and bear No, 4321571 (see chapter 246/1). This starter differs from the others in thet the starter assy Is embodied in the shround For operation on this unit refer to the exploded view (Fig. 2-16/1) Fie 26/1 view 7H angie. Operations on starter To disassemble starter, proceed as follows: 1) Remove the shroud starter assy from the engine by removing the 4 holding screws (see fig. 2-16/2) 2) Pull starter rope about half way and prevent recoll by firmly holding pulley. 3) Tie @ knot on rope (see «a in Fig. 246/3) to prevent recoiling and remove handle (b-c) by loosening the knot fastening the latter to the rope. Fig. 2.16/3. Handle removing 4) Loosen the knot (a) previously tied on rope and let the spring unwind by slowly releasing the pulley. 5) Unscrew retaining ring (+d in Fig. 246/4) and remove brake (e), spring (f), dog (g) and {dog spring (h). Carefully remove pulley (i) making sure that main spring (I) does not escape from its hous- ing (m) The starter will then be completely disas- sembled. Check for damaged parts and replace. Fig. 2.16/4 Removing rtelning tng Before reassembling starter it s important to check main spring for troublefree operation. If the main spring is damaged, remove by sharply striking the starter box on bench, keeping box feet downward to avoid injury by the spring suddenly being re- leased from its housing.To reassemble starter 1). Refit a new spring to its housing by using fa genuine spare part supplied In the special keeper (see fig. 2416/5) Fig. 216/5 A= Spring Rest spring container on inner surface of star- ter housing, locate outer hook of spring (x in fig. 26/6)’ in the appropriate notch in the housing and press spring fully home. Lubricate spring well with soft grease. Fig. 26/7 Fiting the pulley NOTE: Turn the pulley in 2 counterclockwise direction (see arrow in Fig. 2-16/8) to check thet the spring locates in the notch provided. Do not turn the pulley in @ clockwise direction Fig, 2.16/6 Locating the pring. 2 Refit pulley after having wound on the rope leaving the end through the notch (0) provided ‘on the pulley (see Fig. 216/7) Insert putley into the container, making sure that the spring locates in the notch provided 2-134) Re fit dog return spring and the dog, holding _6)_Locate the starter spring by turning the pulley both the spring and the dog as in Fig. 2-16/9 in the starter direction of rotation (see arrow and then press all fully home (r} in Fig. 2.16/8) and then turn the pulley 4 complete turns, as explained at page 2-4 ~ Replacing rope By observing the following procedure a brokyn or damaged rope can be replaced without sis: ‘mantling the starter (see Fig. 2-16/11) Fig 26/9 Locating tur spring 5) Refit brake spring (f) and brake (e) pushing the brake downward with two fingers Insert the retainer ring (d) (see Fig. 216/10) Fig. 2.16/11 Replacing rope 8) Wind up the spring by turning the pulley Ina clockwise direction 4 turns. D Align the pulley hole with the rope outlet holding the pulley as in Fig 246/11 c] Make a knot at one end of a new rope d) Insert the rope in the pulley hole until it protrudes from the outer hole of the starter. Pull the rope to its full extend and make a knot in the middle of the rope to fa- cilitate the fitting of the handle (see Fig. 26/3) @) Loosen the knot and check that the rope can be pulled to its full extend and that It completely rewinds and holds the handle firmly to the starter. Refit the shroud starter assy on th gine after fitting 4 metal bushings in the 4 shroud holes (see Fig. 2416/2) NOTE: In the refitting of the 4 spacers (+ A» in Fig. 2-16/2) fit the two longer ones in the upper holes.4) Refit dog return spring and the dog, holding both the spring and the dog as in Fig. 246/9 ‘and then press all fully home (+) ~ NS We Fig. 2.16/9° tocating retun sping. 5) Refit brake spring (f) and brake (e) pushing the brake downward with two fingers. Insert the retainer ring (d) (see Fig. 216/10) Fig. 216/10 Replnce rope 8) Locate the starter spring by turning the pulley in the starter direction of rotation (see arrow 16/8) and then turn the pulley 4 turns, Replacing rope By observing the following procedure @ broken for damaged rope can be replaced without dis- mantling the starter (see Fig. 216/11) Fig. 2.16/11 Replacing rope. 2) Wind up the spring by turning the pulley ina clockwise direction 4 turns. ) Align the pulley hole with the rope outlet holding the pulley as in Fig. 246/11 ©} Make @ knot at one end of a new rope. 4) Insert the rope in the pulley hole until it protrudes from the outer hole of the starter. Pull the rope to its full extend and make a knot in the middle of the rope to fa- cilitate the fitting of the handle (see Fig. 2-16/3). @) Loosen the knot and check that the rope can be pulled to its full extend and that it completely rewinds and holds the handle firmly to the starter. shroud starter assy on the ef ine after fitting 4 metal bushings in the 4 shroud holes (see Fig. 2-16/2) NOTE: In the refitting of the 4 spacers: (+ A» in Fig. 2-6/2) fit the two longer ones in the upper holes.caren s IGNITION SYSTEM 3-1 GENERAL Ignition system fitted on ASPERA MOTORS 2 and 4 stroke engines, is flywheel! magneto type The unit is contained into flywheel magneto and only HT cable and in case earth wire are external Ignition system is made up by flywheel with builted in magnetic masses and by stator which includes coll, condenser and contact breaker points Different types of flywheel magneto units, all ‘operating in the same way, have been fitted and are fitted at present by Aspera Motors In the followings we will make a short description of different types. ‘Magneto assy type "A (fig. 34/1) Fig. 3.1/1 Magneto assy type "A Heavy magneto assy n° 4110033 Light magneto assy n* 4110035 ‘Supersede type "B” on 2 and 4 stroke engines. The flywheel is of a larger diameter with teeth ‘on the underside for side mounted starter use. Flywheel is the only difference between "A and "'B” types, being the stator unchanged, while regarding "C" type both flywheel and stator change. This magneto Is completly interchangeable eve for the component-parts as regarding type "B Regarding type “Cis only possible to change the complete assembly. Heavy flywheel ne 4111028 Light flywheel n° 4111027 Stator re 4120010 Breaker cam n° 4131003 Magneto assy type "B” (fig. 3-1/2) Fig. 3.1/2 Magneto sey type Heavy magneto assy n° 4110020 Light magneto assy n° 4110019 This type was fitted on two and four stroke en- ines until the end of 1967 season, Regarding type “Cis only possible to change the complete assembly and it is not possible to change the component-parts. As regarding type “A”, this is complete on in- terchangeable both for the assembly and for the component-parts, Heavy flywheel! ne 4111015, Light flywhee! ne 4111016 Stator se 4120010 Breaker cam nv 4131003,Magneto assy type "C" (fig. 3-1/3) Fig. 3.1/3 Magneto Heavy magneto assy n° 4001005 Light magneto assy n° 4001002 This type was fitted to early four stroke engines and is easily recognised by the ring of teeth round the periphery of the flywheel This magneto is now superseded both by type and" B”. the component parts of these magnetos ‘are not Interchangeable but may be changed as a ‘complete assembly Heavy flywheel ne 4111002 Light flywheel ne 4111001 Stator re 4120003 Breaker cam n° 4131001 Magneto assy type "D" (fig. 3-1/4) Fitted to AH81 MS and MD outboard engines: Heavy magheto assy Anticlock nm 4101513 Light magneto assy Anticlock n° 4101504 Heavy magneto assy Clockwise n* 4101519 Light magneto assy Clockwise n° 4101505 The respective types of flywheel are: ne 4111518 - Heavy flywheel - Anticlock re 4111501 - Light flywheel - Anticlock ne 4111524 - Heavy flywheel - Clockwise rm» 4111502 - Light flywheel - Clockwise ne 4120501 - Stator re 4131501 - Breaker cam - Anticlock re 4131502 - Breaker cam - Clockwise 3-2 Fig. 31/4 Magneto a Magneto assy type Fig. 3.1/5 Magneto amy type "E* Fitted to V51- V51M- AHSIMD - AHSIMS old type engines. Heavy magneto assy Anticlock ne 4101516 Heavy magneto assy Clockwise n° 4101517 Light magneto assy Anticlock ne 4101502 Light magneto assy Clockwise n° 4101510 rn 4111521 » Heavy flywheel - Anticlock se 4111504 - Light flywheel - Anticlock se 4111522. Heavy flywheel - Clockwise re 4111510 - Light flywheel - Clockwise ri 4120502 - Stator ve 4131501 - Breaker cam - Anticlock 1 4131502 - Breaker cam — - ClockwiseMagneto assy type "F (fig. 34/6) Fig 34/6 Magneto Fitted to AH47 and AHS8 MD-MS engines. Heavy magneto assy Anticlock n> 4101515 Heavy magneto assy Clockwise ne 4101514 Light magneto assy Anticlock n° 4101507 Light magneto assy Clockwise n° 4101506 re 4111520 - Heavy flywheel - Anticlock se 4111507 - Light flywheel - Anticlock 4111519 - Heavy flywheel - Clockwise sf 4111506 - Light flywheel! - Clockwise re 4120503 - Stator The breaker cam is machined on the crankshaft Magneto assy type "G" (fig. 3-1/7) Fitted to AVA7 engines. 1 3721801 flywheel impellor ‘ 4120503 stator The breaker cam is machined on the crankshaft. 3-2 SPARK CHECKING PROCEDURE 1) Remove spark plug and re-connect high tension lead to plug terminal, earth plug body to ‘engine and with control lever In start position, pull sharply on starter rope and observe spark, at plug points this should be strong and blue in colour (fig. 32/1) 2) If spark does not jump or is weak or reddish in colour, disconnect plug and insert screw- driver into plug cap, hold screwdriver blade Fig. 3.1/7 Magne ay pe "6". about 3 mm. from a good earth on the engine and pull the starter (fig. 32/2). 3) If spark is good, clean or replace plug. 4) If no spark occurs remove plug cap and repeat. Check on H.T. lead, if spark occurs, replac plug cap. ig. 2.2/1 Testing spark at ply 5) If no spark, remove earthing wire from stop control terminal (fig. 9-2/3). Repeat test. 6) If spark occurs check stop control and earth wire. Replace as necessary. If still no spark It Is necessary to remove flywheel. a) Remove air shroud complet b) Remove flywheel nut and starter hub screw completely. Remove flywheel using too! ‘w 8B41501, back off one turn, and sup- porting the flywheel underneath strike puller a sharp blow with hammer. ) Check flywheel key, with: starter.e) Points gap - see table, if adjustment is necessary loose screw securing static point and re-set with feeler gauge. ) Clean contacts with fine emery or contact file. Mig. 32/3. Stop. wie terminal, 9) Remove all traces of oil, if oll is present in the breaker box it will be necessary to renew the crankshaft oll seal © fh) Check all wires and connections. 1) With an ignition tester check the efficiency of the oll and condenser (if a tester is not available it may be necessary to test with new units) Reassemble and carry out spark test, If engine does not properly run, the condenser may be suspect; this is usually indicated by burning of fe’ coraucnal Calwayal replace tar comers Ve points are burned) 3-3 STATOR ASSY SERVICING Detail servicing commencing at chapter 3/1 (ic, 33/1) Fig 33/1 Air shroud removed: Remove flywheel (fig. 33/2) with the aid of spe- cial tool 1 8841501 (fig. 3-3/3]. Check crankshaft and flywheel tapers for craks or distortion. Re- Fig. 3.3/2 Removing Mywhes! outFig 2/2. Pywhaal bneck of too place any damaged parts. Remove dust cover retaining spring (fig. 33/4) dust cover and gasket. Check all wires connections and insulation. A) Breaker points 1) To replace breaker points a) Remove nut securing leads to breaker points "A" (fig. 33/5). Remove breaker by lifting out and simulta- riously easing insulator block “A” from box (fig. 3-3/6) b) Detatch static point by removing secu: ring screw "A" (fig. 33/7). ¢) Inspect points and replace as neces- sory. ¢) Position static point in box and locate with securing screw leaving screw loose for adjustment. 3/4 Dune cover eetaning spring. Fig. 3.3/5 Ramering twrminal @) Fit moving point, secure with nut and reconnect wires. 2) Cleaning points To clean the points in position: a) Rotate engine until points are open. Insert a piece of smooth emery. b) Close points in order to grip emery - ‘and clean, ©} Open points and remove all traces of dust (fig. 33/8) 1. 3.3/6 Removing points and inulater. 3) To adjust points a} Adjust point gap to 0.45 + 0,50 mm. (.020") as follows (see Breaking point setting table), b) Tum engine to bring cam heel to widest opening point.Fig 33/7 Removing sale pein. ©) Insert feeler gauge with the screw driver fitted in slot fig. 33/9 Gently close points until a “ drag" Is felt on the feeler. Tighten points securing screw. A” see 8) Colt 1)°Coil inspection a) Inspect coil for damage, craks, bad insulation oF signs of overheating. Check all leads. particularly at point ‘of entry to coll ) Check coll efficiency on a tester with coil mounted on stator. Fig. 33/9 Adjuting the point. ig. 33/10 Connection required chuck magneto coil ines: Intton Fig. 3.3/8 Cleaning polnt. Fig 23/11 Coll ratainng methods,Fig. 23/12 Diconnecing cil wires ©) Check coil outer insulation for leaks with tester (fig. 33/10}. Ifa tester is not available, the engine may be tested with @ new coil. ©) Condenser 1) Checking 4) Check for dents or other dams b) Check condenser efficiency with tester. 2) Condenser replacement (fig. 33/12) a) Unsolder wire from connection "A". b) Remove wire from hole ” 8 ) Remove condens: Reverse procedure for refitting Note: During soldering op tab from screw in order to prevent damage to insulator “A” (fig. 3/12) Fig 23/13, Removing ceil 2) Coll replacement a) Remove by releasing retainer spring "A" (fig. 33/11) or by streigh- tening the lamination of the core "B (fig. 33/11). b) Disconnect al leads and unsolder tab Aw (fig. 33/12) ©) Pull coil from stator. 4) Completly detach coil (fig. 33/13). Reverse the procedure for refitting. Fig. 33/14 Cover retain D)_ Other types of stator assy Stator type "C" Basic difference from type “A” and "B” Fig. 23/15 Removing coil esd.a) Dust cover clamping spring is of different type “A (fig. 33/14), ) The coll is earthed to the stator by means of a tab inside the fitting hole, ) Removal of coil is by releasing retainer spring "A" (fig. 23/18) Disconnecting LT. lead at points ' 8” (fig. 33/18). Remove condenser by screw "A" (fig. 33/15) Stator types "D" -"E". "F". Service as previous types. 3-4 IGNITION TIMING A) General All engine are correctly timed before delivery and the timing marked as in fig. 3-4/1, Note: On types "F"-"G" the stator is fixed and no adjustment is possible ig, 3.4/1 ti timing marks B) Two stroke timing 1) Set breaker points to 0.45 = 0,50 mm, (20). 2} Remove plug, insert a narrow rule on to piston top, place @ streight edge across top of cylinder (fig. 3-4/2) (a special tool lable for this operation) 3) Turn crankshaft in direction of rotation and bring piston to top dead centre (indi cated by position of rule against streight ‘edge or indicated on scale of special tool. 4) Refer to table for correct amount of ad- vance. Turn engine in reverse direction until this is obtained, denoted by rule po- sition against streight edge. Fig. 3.4/3. igion timing special tool. sto" Pip 44/4 Marinised enpns ignton cone5) Slacken stator securing bolts and turn Until points are just ebout to open, if a {est light is not available for this operation, insert a piece of cigarette paper between the points and tum until paper Just be- comes free, at this point lock stator. C) Outboard engines (TA-VA-AHB1) Engines for this application are fitted with a control to vary the ignition timing in relation to the engine speed. The stator is mounted on a movable plate controlled by @ hand lever, and is also con- nected to the throttle control, thus regulat- Ing the timing In relation to the amount of throttle opening (fig. 3-4/4). The max ignition timing should not exceed that given In the table and Is checked with the lever in the max position. Note: Later types of marine engines are not fitted with a stop switch, the lever being moved to the full retarded po- sition to stop the engine. Four stroke timing Accurate timing is best achieved by removing the cylinder head and gasket, turn engine to top dead centre and using gauge (fig. 3-4/5) set timing following the procedure for two stroke engine ‘special tools n° 8841510 and 8841033 are available for this operation (fig. 3-4/6) Fig 24/5 Ignition ming. Fig. 24/6 Four stroke timing tesIGNITION SYSTEM FOR ZH ENGINE 3-5 General Fig. 35/1 shows the main features of the Ignition System fitted to the ZH engine. The Ignition System comprises @ flywheel with 4 built in magnetic mass and a stator assembly which includes coll, condensor and contact breaker points. 2H engines have the breaker cam machined on tne crackshaft (see Fig. 3-5/2) Unit checking procedure The details as In chapter 3.2 apply. Ignition system checking procedure Instruction given in chapter 3-3 apply with certa changes due to the different configuration of the unit (see Fig. 3-5/1 and 3-5/2) Ignition timing On ZH engines the stator is non-adjustable. Set breaker points to .023". Eorthing wire ‘The engine is stopped with the governor lever in stop position. The earthing wire coming trom the ignition ‘coll Is fixed at the carburettor control plate (see fig. 35/3, part = B+). Fig. 2.5/9 Unking wire Being the air intake manifold of plastic with iso- lating features, there Is @ wire linking the carbu- rettor control plate with the cylinder. This wire is mounted under the fixing screw of the air Intake manifold and under the carburettor control plate (see fig. 35/3. part « C ») Spark Plug: The spark plug to be used is of the type Champion C8 or Bosch WKA 17573. 3403-6 SOLID STATE IGNITION FOR Crankshatt H-LAV-TA-VA ENGINES The flywheel Is Identical to the standard ignition system but does necessitate a special crankshaft owing to the fact that the keyway is differently Commencing in the 1969-70 season, Aspera Motors positioned. See fig. 3-6/3 and 36/4 will offer solid state ignition as an alternative to the standard fiywhee! magneto. The solid state system embodies no friction pro: ducing or wearing parts, Ignition timing is none adjustable on this system. Magneto Assembly Fig. 36/1 shows the solid state ignition, which is designated part number 4120012 and is comprised of the following parts (see fig. 36/2) fg. 24/3 A = Solid sate cankahah heyway The solid state ignition crankshaft is recognizable by the fact tha: the keyway is of the woodrutt type (flywheel sidef Fig. 36/1 Solid state Haiton sty. c= sa ‘stsrnbly NY 4150012 Fi, 3-6/4 Standard ignition crntahatt heyy.Spark Checking Procedure For spark checking procedure proceed as in chap- ters 32, pages 33 and 34 and as follows:— a) Visual check Terminal no. 4 is the earth connection, 1) Visually check that the low tension (red lead) is not earthed (1) and is connected to the solid state assembly (c) at termi- nal (5), Also check that the wire is not shorting. 2) Inspect the high tension lead for crakes or Indication of arcing 3) Check that the terminal (3) on the solid state assembly is securly soldered to the core laminations. 4) Ensure that the earth lead is securly con- If test is not available, the engine should be tested using a new coil, 2} Using a tester, check the coll outer insu- lation for leaks. 3) Replace the coil if found defective. If the coll Is not defective replace the solid state assy (c). ©) Coil Replacement 11 Strengthen the lower lamination of the core. 2) Disconnect the earthing wire from the pri- ‘mary winding terminal of the coil and pull coil from the lamination core. Reverse the procedure for refitting nected to terminal (4), Replacement of the Solid State Assembly 1) Strenghten the lower lamination of the core. b} Coil Inspection 1) If all connections are correct and no spark ‘occurs, check the efficiency of the H.T. coil by means of a coil tester, this test must be carried out with the coll mounted on the “core laminations. 2) Unsolder the earth terminal (3) fig. 3.6/8 from | the lamination core, Pull solid stete core. Reverse the procedure for refitting 3y (€) from the lamination Fig. 26/5 2-4-19703-7 COIL WITH BUILT-IN CONDENSER Aspera Motors have introduced a new improvement to the present ignition system, The condenser being in unit with the coil and completely sealed within the coil insulation shows No, 4120010. the standard stator assy Part Fig. 2 ‘shows the new stator with builtin condenser Part No. 4120017 which can be easily recognised by the bulge in the coil where the condenser is housed. Servicing Details of servicing are described in the Mechanic's Handbook Chapter 3- Ignition System pag. 3-3. Checking The procedure for the checking of the coil with built-in condenser is the same as that on the standard stator with separate condenser, with the exception of the condenser efficiency test. If a tester for coil checking is not available, operate as follows 1) Visually check all leads for cracks. 2) Ensure that points are in good condition, If everything is satisfactory and the stator has ne spark, replace the coil A — Primary earthing wire B ~ Primary wire terminal © ~ Separate condenser fixing hole. Coil Replacement 1) Disconnect the primary earthing wire trom the lamination core (A in Fig, 3) 2) Disconnect the primary wire from the terminal (B in Fig, 3) 3) By means of @ pair of pliers strengthen the lamination of the core and remove’ coil Reverse the procedure for refitting N.B. In case of none availability of the coil with built-in condenser, the separate coll and the ‘condenser of the standard type may be fitted, ‘The hole C in Fig, 3 has been retained for fixing ‘the condenser by means of the screw No, 9199063. 3.13 4s38 LIGHTING GENERATOR FOR ASPERA ENGINE Goneral Description ‘The lighting stator differs from the standard stator as shown in fig. 3-8/1 - part Nos 4120013. Fig. 3-8/1. lighting stator assy. A ~ Stop lights coil. B — Lights coil ‘The flywheel also differs from the standard flywheel by the different Nos.of magnet inserts. 12 magnets are incorporated as shown in fig. 38/2. Fig, 38/2 flywhee! lights The lighting flywheel for engine models H & LAV. 25-30-35 and model TA & Va is part Nos 4111044, ‘The lighting flywheel for engine HS40 and LAV4O is, part Nos 4111067. 19.1971 Stator : Fig, 3-8/3 shows the complete stator. The coil (C) is connected by a red wire to the brake stop lights, ‘The coil {D) is connected by a black wire to the lighting switch and so to the lights. Al ignition parts are identical to the standard sy- stdin, Fig. 38/3 © ~ Stop lights coll (red wire). D — Lights coil (black wire). Service: Check aff wires and connections. If found correct, check coils for continuity with suitable meter as follows ‘Stop coil 1. Connect one wire of meter to earth. 2. Connect the other wire to red terminal. 3. If continuity is in order this will be indicated by ‘the movement of the meter, if the meter shows no reading, the coil must be changed. Lighting Coil : Check as 1, 2 & 3, operating with black instead of red Replacement ‘The lighting stator and flywheel is interchangeable with the standard units NoTE ‘The stop and lighting coils are different and may be changed individually. a43.9. IGNITION SYSTEMS FOR AV 520-600- 750 ENGINES The new 2stroke AV 520-600-750 engines may be fitted 1) With standard ignition system. 2) With solid state ignition. ‘The standard arid the solid state ignition as well as the fiywheel are identical to those already fitted to TA, and VA engines and to 4-stroke LAV-H engines. While the solid state ignition timing is non-adjustable Fig. 39/1 A = standard keyway ignition crankshatt 121973 and necessitates @ special crankshaft (see Chapter 3-6), the standard ignition system must follow the timing dimensions given below AV 520 2,8 mm. 3/32 AV 600 2/5 mm. 3/32 AV 750 2,5 mm. 3/32 Fig. 3-9/1 and 3-9/2 show the different shape and tition of the keyway in respect to the erank pin position, ‘The key on the crankshaft (standard ignition system A in fig. 3-9/1 — solid state ignition system B in fig. 3.9/2). Note : AV 525:605-755 marine engines are fitted only with solid state ignition system. Fig.39/2 8 solid state crankshaft keyway 345IGNITION SYSTEM TABLE OF SPECIFICATION Timing Dimensions | Breaker point setting Spark plug Engines Models ; ia ‘itimeter | inches | Millimeter | Spare Parts Relevant cree mm. ae mm. | catalog. No. Spark plug 2 Stroke Engines TA 9/64 3.50 020 050 TA- Marine 5/32 400 020 080 TH 9/64 350 020 0.50 4149004 | Champion J 8J vA 9/64 3.50 020 0.50 4yago11 | Bosch W175 T3 VA- Marine 8/32 4.00 020 050 44149009. | Marelli CW 175 JC AHAT 5/32 400 16 00 avar 3/32 4.00 016 0.0 ) {142001 | Champion seu AH 58 5/32 4.00 020 050 ; 4149013 | Bosch W240 73 4149010 | Marelli CW 260 JC 4149001 | Champion J6J AH at 11/64 435 020 050 4149012 | Bosch W225 13 AH 8t -Marine 11/64 4.35 020 os 4149010 | Marelli CW 260 JC 4 Stroke Engines LVAAV Vertical crankshaft Models 22-25 -30-35, 16 158 20 050 |) H- Horizontal 4149008 | Champion J8 crankshaft anne 4149011 | Bosch W175 13 22-25-30 16 150 020 050 ‘4149007 | Marelli CW 175 P Model 1-35) 040 470 020 oso |) Note: Spark plug Gap. 030 NOTE: The condenser capacity should not be less than 0,16 microfarads, all models, END CHAPTER 3CHAPTER 4 FUEL SYSTEM 4-1 AIR CLEANERS (Owing to the nature of the work for which an air cleaner is designed, it follows that it must have a direct effect on the carburation. It is, therefore, essential that It is kept perfectly clean ‘and correctly maintained at all times. Its function Is to protect the inner parts of the engine from dust particles present in the air, a condition which Is generally aggravated by the operation of the machine. ‘Should the sir cleaner maintenance instructions not be strictly adhered to, dirt and dust collected In the cleaner could enter the engine or cause ‘overchoking resulting in too rich a fuel mixture. Both the above conditions reduce engine life These Impurities In a 4-stroke engine or admitted in the mixture of @ 2stroke engine, form an abrasive which promotes excessive wear to mo- ving parts, When a 4-stroke engine becomes over-choked due to a dirty air cleaner, an excessive amount of petrol is drawn into the cylinder, flushing the cylinder walls, resulting in insufficient lubrication. It Is therefore important that operators observe the instructions on air cleaner maintenance. Engine operation is impaired by an air cleaner in bad condition and no warranty is granted to users who do not carefully follow the air cleaner ser- vicing instructions. 4-2 TYPES OF AIR CLEANERS AND SERVICING METHODS Aspera engines are fitted with the following types of air cleaners: a) b) ° @) Aluminium foil air cleaner. Polyrethane foam alr cleaner. il bath air cleaner. Special dry type air cleaner for 2:stroke chain- saw engines. e) Polyurethane sir cleaner with stocking pre- filter for Flymo lawnmowers. ) Polyurethane air cleaner with plastic prefilter for Flymo lawnmowers. 9) Polyurethane air cleaner with snorkle. h) Baffles for marine engines. Fig. 42/1 Aluminium fell cleaner, ) Aluminium foll alr cleaner. This consists, as shown in fig. 42/1, of @ metal {oll element held in its housing by a spring retainer ring. A screen In the base of the housing prevents the metal foil from being drawn into the carbu- rettor. Maintenance of this air cleaner is carried out by flushing the metal foil in petrol or solvent. After cleaning, dry and reoll the mesh, making sure that the lubricant Is evenly distributed throughout, bb) Polyurethane type air cleaner. This consists, as shown in fig. 4-2/2, of @ poly: rethane foam element retained in Its housing by @ cover. A metal grill Is fitted in the base of the container to prevent the element being drawn into the engine, Maintenance of this type is carried out by washing the polyurethane foam element in petrol (a mixture of water and household detergent may also serve this purpose, providing that the element is thoroughly dried before re-oiling). (Should the foam element be excéssively impre- gnated with dirt, after prolonged use, replace it.) After this cleaning operation, wet the polyu- rethane foam with a spoonfull of mineral oil and Fig 42/2 Polyurethane lesner.‘squeeze It lightly to obtain a uniform distribution of the lubricant through the element, Clean the container and re-it the alement. €) Ol bath air cleaner. This consists of a bow! containing oil into which a metal foil element is fitted (see fig. 42/3). Service by removing the bowl, clean out any sediment in the oil bath, wash the element petrol, top up oil level, and re-assemble Fig 42/2 ob ) Dry type air cleaner. This type consists of a cylindrical element of laminated fibre (see fig. 4.2/4) and is generally used on chain-saws. Clean the element by com- pressed air, or alternatively by tapping on a hard surface. Ort OO- Fig. 42/4 Ory fre cleaner * ) Polyurethane cleaner with stocking pre-filter for Flymo lawnmower. ‘Owing to the particular features of the Flymo lawnmowers, two types of predilters have been fitted. COOOwo Fig. 42/3. Polyurethane type with “stocking preclonner. Firstly, in addition to the standard polyurethane alr cleaner, a «stocking» presilter was fitted, which consists of a small bag (stocking) of cloth which is kept in shape by @ spring located in the air cleaner cover and seated in the stocking itself (see fig. 42/5). With this filter unit, servicing is carried out on the filter element, as for the standard polyurethane alr cleaner. Should the « stocking » become clogged, the blager particles may be shaken out, and, If necessary, the sock washed in soap and water and allowed to dry. 1) Polyurethane air cleaner with plastic pre-ilter for Flymo lawnmower. ‘Subsequent to the stocking pre-filter, a plastic prefilter has been fitted (see fig. 42/6). The filter element of this is serviced exactly as the previous one, except that the plastic pre-cleaner should be washed in petrol. The function of the pre-cleaner is to draw in alr from an erea in wh:ch any impurities are travelling at @ high speed in @ counter direction to the pre-cleaner intake. By this method, a minimum amount of dirt is drawn into the element, C2. DOD 1 6 a Fig 42/6 Polyurethane type with plete preseane. Ensure that the pre-filter is both correctly posi- tioned, and seated on the container otherwise air may be drawn in from a turbulent zone, with ‘consequent « clogging» of the cleaner element.Note: For 1965 model Flymo mowers, the sock type preccleaner may be replaced by this plastic pre-cleaner Part No. 1511521 and fixed jet No. 3941510, available as a con- version kit. Fig. 42/7. Snorkle type preleaner. 9) Polyurethane air cleaner with snorkle. ‘A snorkle type pre-cleaner Is available to meet the requirements of manufacturers of equipment operating in extremely dusty conditions. This consists (see fig. 42/7), of a standard polyu- rethane filter with a specially shaped cover to is attached @ plastic hose, carrying at the Intake end, a paper cartridge filter. The advantage of this type of filter Is to take in air from a point where dust is at a minimum. Servicing of this assembly is carried out in three stages: ‘1st Stage) Paper air cleaner. Clean paper filter by compressed air or by tapping on a hard surface. Replace If excessively clogged. 2nd Stage) Hose. Wash hose from Inside with a flow of water and detergent to remove any dust deposits. Std Stage) Polyurethane element. Service as for other types, Fig 42/8 Marine angine ba hh) Baffles for marine engines, Engines supplied for marine use are not fitted with air cleaners. Such engines are equipped with a baffle located at the carburettor inlet (see fig. 42/8)4-3 CARBURETTORS Two basle types of carburettors are fitted to Aspera engines, 4) Diaphragm carburettor. b) Float carburettor. ‘The operating and constructional differences of these types of carburettors are as follow: ) Diaphragm type carburettor. Fig. 4-3/1 clearly illustrates the operation of the diaphragm type carburettor In the various post: tons of: (A= choke) (B - idle) (C - intermediate speed) (0 - full load). Inlet of petrol to the carburettor is controlled by needle «P+. During operation of the engine, this needle is lifted by diaphragm « L», when the fuel drawn from the jet nozzles cause a depres: sion on the upper part of the diaphragm. 8 Pu a Ong le c oO a ni ® GEL o. - 3) ® Fig. 43/1. Diaphragm carburetor operation.) Float type carburettor. Fig. 43/2 illustrates the operation of the fioat Inlet of petrol to the carburettor is controlled by type carburettor in the positions of: needle «P+. When the petrol level decreases, (A. choke) (B - idle) (C - intermediate speed) the float « G-» falls and consequently the needle (0 - full load). allows petrol to flow in and restore the level, Fig. 43/2. Flea carburator operation.4-4 DIAPHRAGM CARBURETTOR There 1, Standard carburettor, fitted on 2 and 4 stroke engines. re three types of diaphragm carburettor: 2. Carburettor with primer, fitted on 2 and 4 stroke engines. 3, Carburettor with pump, fitted on chain-saw ‘engines or in any application which requires the petrol tank in @ position below the level of the carburettor. A) Adjustment of primer type and standard car- bburettor. For carburettors with variable main and idle jets, proceed as follows (fig. 44/1 refers) 4. Tighten the main adjustment needle « A» and Idle adjustment needle «B+. (Do not use force or the needle seats may be damaged) 2. Turn main adjustment needle +A» (hex head) 1% turns anticlockwise. Turn idle adju- stment needle « B+ (knurled head) 1 turn ant clockwise. Back off idle speed regulating screw +C so that it is out of contact with the throttle stop lever (fully closed throttle), then screw in one full turn to hold throttle |_ slightly open. 3. Move control lever to full choke, or actuate primer. Start engine and allow to warm up. Make sure choke, when provided, is ‘ully open after warm up, 4-6 4. Run engine at full operating speed and, by final careful adjustment, set main adjustment needle «A» to position that will give smoothest Performance. Final adjustment should range between one and one and a half turns open. '5. Run engine at idle speed and adjust idle screw +B. to position that will give the smoothest Idle operation, 6. Adjust idle speed regulating screw «C= to ‘give an idling speed of 1800 rpm. Use a tacho- meter to check speed. Carburetors fitted with a fixed main jet «E+ are now standard, ‘and the only adjustments possible are to the Idle jet and slow running screws. Note: The final setting should give @ slightly rich mixture, Carry out this operation according to item 5 above. {See bulletin No. 505162) 8) Adjustment of diaphragm carburettors with pump for chain-saw engines. (On chain-sew carburetors (see fig. 44/2), a semi fixed main jet +C» Is provided which, instead of calibrated hole, consists of @ tapered plug which méters the fuel worm condition terminal vari fed jt The fuel mixture should, in fact, be very rich and the engine running speed should never exceed 7000 rpm. Setting of the fuel mixture is effected by adding or removing shims, (Part A of fig. 44/2) fitted between the main adjustment screw and the carburettor body, thus controlling the fuel mixture ‘The addition of shims richens the mixture and thus lowers the engine speed. By removing shims the opposite effect is obtained, so that by this method, the desired mixture and speed are obtained. Note: For pump operation, refer to fig. 45/10.4-5 SERVICING A) Standard diaphragm carburettor. To clean carburettor (see fig. 4-5/1) proceed as follows: 1. Remove main jet (Part No. 14-1546-17) and Idle jet (Part No, 10-11-12-13). Check these for serviceability. replace worn or damaged jets. (On current carburettors, a fixed main jet is now fitted (8). This Is fitted without seals etc., whereas the idle jet Is adjustable and consists of a needle (10), spring (11), O-ring (12), and washer (13) 2. Check that throttle (3 end 9) and spindles (1 ‘and 7) operate freely. If any sticking occurs, clean, and, if necessary, replace defective parts. 3. Replace the carburettor if the body Is found damaged or broken. 4. Remove the 4 screws (26) of cover (25), re- move the gasket (23) and diaphragm (24). At this point, check visually the gasket and diaphragm. The latter should be in good con- dition and not cracked or hardened. 5. Remove the valve assembly (18-19-2021) with ‘a hexagonal 5/32 spanner, (or with a slotted head screwdriver for valves of old type). Fig 45/1 5/2 Removing needle any. taking care to extract the washer, spring ete. (see fig. 45/2). Compressed air may now be blown through the valve seat hole and through the two Jet holes to remove any dirt or blockage, 6. Re-assemble, referring to fig. 4-5/1, making sure that valve (21) and needle (19) are not da- maged or bent. The needle (19) should pro- trude approx. level with the carburettor face, see fig. 4-5/3. If needle Is sunk, this denotes that gasket (20) has not been fitted or that the needle is worn. If needle projects, it is possible that two washers have been fitted. 2 Fig. 45/3 Neadle vale sting,