CHOKE KNOB/THROTTLE SENSOR

Loosen the lock nut and remove the choke knob.

CHOKE KNOB

CHOKE KNOB/THROTTLE SENSOR

Check the valve for damage or stepped wear.

CHOKE KNOB/THROTTLE SENSOR

VALVE

CHOKE KNOB/THROTTLE SENSOR

’05, ’06 shown:

THROTTLE POSITION SENSOR

’05, ’06:

Remove the torx screw and throttle position sensor. After 06:

Remove the bolt and throttle position sensor.

• When removing the throttle position sensor, mark the sensor position ensure that it is rein­stalled in the original location.

• The throttle position sensor is factory pre-set and no adjustment is necessary unless the throttle position sensor is replaced.

For sensor inspection (page 18-9) and replace­ment (page 6-26).

ACCELERATOR PUMP/FLOAT/JETS

SCREWS

COVER

CHOKE KNOB/THROTTLE SENSOR

’05 — ’07 shown:

Remove the screws and accelerator pump cover. NOTE:

• The accelerator pump cover is under spring pres­sure.

• Do not lose the screws and O-ring.

Remove the spring, diaphragm, D-ring and O-ring.

D-RING

O-RING

CHOKE KNOB/THROTTLE SENSOR

DIAPHRAGM

Remove the screw and throttle stop screw stay. Remove the screws, hose guides, and float cham­ber.

GUIDES

STAY

O-RING

CHOKE KNOB/THROTTLE SENSOR

FLOAT CHAMBER SCREWS

Remove the O-ring from the float chamber.

’05 -’06 shown: «Жл ADJUSTING SCREW

CHOKE KNOB/THROTTLE SENSOR

Pull out the push rod while holding the push rod link lever.

Check the diaphragm for deterioration or pin hole. Check the spring for damage or fatigue.

Check the push rod for wear, bends or damage.

PUSH ROD

SPRING

CHOKE KNOB/THROTTLE SENSOR

CHOKE KNOB/THROTTLE SENSOR

DIAPHRAGM

FLOAT VALVE

FLOAT

CHOKE KNOB/THROTTLE SENSOR

Remove the float pin, float and float valve. Check the float for damage or fuel in the float. Replace the float if necessary.

Check the float valve and valve seat for scoring, scratches, clogs or damage.

FLOAT VALVE

CHOKE KNOB/THROTTLE SENSOR

A worn or contaminated float valve will not seat properly and will eventually flood the carburetor.

Check the tip of the float valve where it contacts the valve seat, for stepped wear or contamination.

Check the valve seat for wear or damage.

Clean or replace them if necessary.

BAFFLE PLATE PILOT SCREW

MAIN

STARTER JET ’05-’07 Shown:

CHOKE KNOB/THROTTLE SENSOR

Remove the following:

— Main jet

— Needle jet

— Baffle plate

— Starter jet

— Slow jet

Damage to the pilot screw sear will occur it the pilot screw is tightened against the seat.

Before removing the pilot screw, turn it in, counting the number of turns until it seats lightly so you can return the pilot screw to its original position when reassembling.

Remove the pilot screw, spring, washer and O-ring.

ACC. PUMP BYPASS

SLOW AIR JET

CHOKE KNOB/THROTTLE SENSOR

05 — ‘07: Remove the slow air jet.

Remove the acc. pump bypass from the float cham­ber.

Blow open the acc. pump bypass and fuel passage with compressed air.

Check the acc. pump bypass for clogs or damage.

Blow open all jets with compressed air.

Inspect each jet for clogs, wear or damage and replace them if necessary.

Check the pilot screw for stepped wear or damage. Check the spring for fatigue or damage.

Replace them if necessary.

SLOW JET

PILOT SCREW

SLOW AIR JET

(’05 — ’07)

CHOKE KNOB/THROTTLE SENSOR

NEEDLE JET STARTER JET

CHOKE KNOB/THROTTLE SENSOR

MAIN JET

Blow open all carburetor body openings with com­pressed air.

SLOW AIR JET (’05 — ’07)

TOP COVER

THROTTLE POSITION SENSOR

O-RING

THROTTLE VALVE

CHOKE KNOB

CHOKE KNOB/THROTTLE SENSOR

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