Pioneer 1200, Maintenance Service Manual

Page: 215 / 300

FUEL SYSTEM Carburetor
2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 14-3
14
NOTE: Make sure the fuel bowl gasket (9) remains properly seated in the carburetor body when the fuel
bowl is removed.
Keep the float pivot pin (6) with the carburetor body after the fuel bowl is removed.
6. Remove the main jet (8) from the carburetor body and discard it.
NOTE: Keep the fuel nozzle (7) with the carburetor body after removal of the main jet by positioning the
carburetor upside down during main jet removal.
7. Select the proper size main jet. See chart on page 14-1. Check the size designation on the jet to make
sure it is the correct part.
8. Install the new main jet and tighten it to 12 in-lb (1.4 N·m). See following CAUTION and NOTE.
CAUTION
• Do not remove the valve/spring assembly from the float assembly. Doing so will damage the
spring.
NOTE: Inspect the main jet nozzle (7) and pilot jet (4) to ensure they are free from contamination. Replace
any part that is clogged. Replace the float or float valve if damaged or worn. Confirm the float valve/
spring assembly is installed correctly.
9. Install the fuel bowl and position with aligning marks made in step 4. See following CAUTION.
CAUTION
• Make sure the fuel bowl is properly seated against the carburetor fuel bowl gasket, and the
gasket is not pinched.
10. Install the fuel bowl retaining screw and tighten to 61 in-lb (6.9 N·m).
11. Write the size of the main jet on the fuel bowl with an indelible ink marker in a location that will be visible
when the carburetor is installed on the engine.
12. Loosely attach the throttle return spring (11) to the carburetor throttle (12) and throttle bracket (4).
13. Install the carburetor (12), gasket (10), throttle spring (11), bracket (4), gaskets (1) and (3), and carbu-
retor insulator (2) onto the maniford bolts (18) (Figure 14-2, Page 14-4).
14. Install the intake pipe gasket (16) (check for proper orientation) and intake pipe (17).
15. Attach the carburetor retaining nuts (19) and tighten them to 50 in-lb (5.7 N·m).
16. Lower the floor jack from under the engine mounting plate, allowing the front bracket snubber to return
to normal condition (Figure 14-1, Page 14-2).
17. Connect fuel supply line (26) and tighten screw clamp to 9 in-lb (1.0 N·m) (Figure 14-2, Page 14-4).
18. Install carburetor vent line (14) and clamp (13).
19. Install the governor cable clevis pin (24) and cotter pin (25).
20. Install the intake hose (23) and secure with hose clamp.