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TH23/TH26/TH34

2Stroke Air-Cooled Gasoline Engine

Service Manual
All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any
form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of
Quality Assurance Department/Consumer Products & Machinery Group/Kawasaki Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been
taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such
changes to products manufactured previously.
All information contained in this publication is based on the latest product information available at the time of publication.
Illustrations and photographs in this publication are intended for reference use only and may not depict actual model
component parts.

Kawasaki Heavy Industries, Ltd., 1999

Second Edition (1) : Apr. 30, 1999 (K)

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LIST OF ABBREVIATIONS
A

ampere(s)

lb

pounds(s)

ABDC
AC
ATDC
BBDC
BDC
BTDC

C
DC
F

F
ft
g
h
L

after bottom dead center

alternating current
after top dead center
before bottom dead center
bottom dead center
before top dead center
degree(s) Celsius
direct current
farad(s)
degree(s) Fahrenheit
foot, feet
gram(s)
hour(s)
liter(s)

m
min
N
Pa
PS
psi
r
rpm
TDC
TIR
V
W

meter(s)
minute(s)
newton(s)
pascal(s)
horsepower
pound(s) per square inch
revolution
revolution(s) per minute
top dead center
total indicator reading
volt(s)
watt(s)
ohm(s)

Read OWNERS MANUAL before operating.

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EMISSION CONTROL INFORMATION

To protect the environment in which we all live, Kawasaki has incorporated exhaust emission control systems (EM) in
compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources
Board.
Exhaust Emission Control System
The exhaust emission control system applied to this engine consists of a carburetor and an ignition
system having optimum ignition timing characteristics.
The carburetor has been calibrated to provide lean air/fuel mixture characteristics and optimum fuel
economy with a suitable air cleaner and exhaust system.

TAMPERING WITH EMISSION CONTROL SYSTEM PROHIBITED

Federal law and California State law prohibits the following acts or the causing thereof: (1) the removal or rendering
inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of
design incorporated into any new engine for the purpose of emission control prior to its sale or delivery to the ultimate
purchaser or while it is in use, or (2) the use of the engine after such device or element of design has been removed or
rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below:
Do not tamper with the original emission related part:

Carburetor and internal parts

Spark plugs
Magneto or electronic ignition system
Fuel filter
Air cleaner elements

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Foreword
This manual is designed primarily for use by trained
mechanics in a properly equipped shop. However, it contains enough detail and information to make it useful to the
owner who desires to perform his own basic maintenance
and repair work. A basic knowledge of mechanics, the
proper use of tools, and workshop procedures must be
understood in order to carry out maintenance and repair
satisfactorily. Whenever the owner has insufficient experience or has doubts as to his ability to do the work, all
adjustments, maintenance, and repair should be carried
out only by qualified mechanics.
This manual covers models: TH23D/TH26D/TH34D.
As for safety information, specifications, exproded view,
assembly and preparation, operating instructions, and
periodic maintenance; this manual does not mention them
as you can depend upon their respective owners manuals
and parts catalogues to tell you the details.
In order to perform the work efficiently and to avoid
costly mistakes, read the text, thoroughly familiarize
yourself with the procedures before starting work, and
then do the work carefully in a clean area. Whenever
special tools or equipment are specified, do not use
makeshift tools or equipment. Precision measurements
can only be made if the proper instruments are used,
and the use of substitute tools may adversely affect safe
operation.
To get the longest life out of your equipment.
Follow the Periodic Maintenance Chart in their respective owners manual.
Be alert for problems and non-scheduled maintenance.
Use proper tools and genuine Kawasaki engine parts.
Genuine parts provided as spare parts are listed in the
Parts Catalog.
Follow the procedures in this manual carefully. Dont
take shortcuts.

Remember to keep complete records of maintenance

and repair with dates and any new parts installed.

How to Use this Manual

Whenever you see these WARNING and CAUTION
symbols, heed their instructions! Always follow safe
operating and maintenance practices.

This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of
life.

CAUTION
This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction
of equipment.
This manual contains four more symbols (in addition to
WARNING and CAUTION) which will help you distinguish
different types of information.

NOTE

This note symbol indicates points of particular interest for more efficient and convenient operation.

a procedural step or work to be done.

Indicates
Indicates a procedural sub-step or how to do the work
of the procedural step it follows. It also precedes the
text of a WARNING, CAUTION, or NOTE.
Indicates a conditional step or what action to take based
on the results of the test or inspection in the procedural
step or sub-step it follows.

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GENERAL INFORMATION 1-1

General Information
Table of Contents
Before Servicing.................................................................................................................................................................1-2
General Specifications ....................................................................................................................................................... 1-4
Idling Speed ....................................................................................................................................................................... 1-5
Periodic Maintenance Chart...............................................................................................................................................1-6
Tightening Torque...............................................................................................................................................................1-7
Clearance Table..................................................................................................................................................................1-8
Setting Table.......................................................................................................................................................................1-9

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1-2 GENERAL INFORMATION
Before Servicing
Before starting to service the engine, carefully read the applicable section to eliminate unnecessary work. Photographs,
diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever necessary. Nevertheless,
even a detailed account has limitations, a certain amount of basic knowledge is required for successful work.

Especially note the following:

(1) Dirt
Before removal and disassembly, clean the engine. Any dirt entering the engine, carburetor, or other parts, will
work as an abrasive and shorten the life of engine. For the same reason, before installing a new part, clean off any
dust or metal filings.
(2) Tightening Sequence
Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to
a snug fit. Then tighten them evenly, in a staggered sequence. This is to avoid distortion of the part and/or causing
gas or oil leakage. Conversely, when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter
of a turn and then remove them. Where there is a tightening sequence indication in this Service Manual, the bolts,
nuts, or screws must be tightened in the order and method indicated.
(3) Torque
When torque values are given in this Service Manual, use them. Either too little or too much torque may lead to
serious damage. Use a good quality, reliable torque wrench.
(4) Force
Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especially
difficult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap
lightly using a wooden or plastic-faced mallet. Use an impact driver for screws(particularly for the removal of screws
held by a locking agent) in order to avoid damaging the heads.
(5) Edges
Watch for sharp edges, especially during major engine disassembly and assembly. Protect your hands with gloves
or a piece of thick cloth when lifting the engine or turning it over.
(6) High-Flash Point Solvent
A high-flash point solvent is recommended to reduce fire danger. A commercial solvent commonly available in North
America is Standard solvent(generic name). Always follow manufacturer and container directions regarding the use
of any solvent.
(7) Gasket, O-Ring
Do not reuse a gasket or O-ring once it has been in service. The mating surfaces around the gasket should be
free of foreign maker and perfectly smooth to avoid oil or compression leaks.
(8) Liquid Gasket, Non-Permanent Locking Agent
Follow manufacturers directions for cleaning and preparing surfaces where these compounds will be used. Apply
sparingly. Excessive amounts may block engine oil passages and cause serious damage. An example of a
nonpermanent locking agent commonly available in North America is Loctite Lockn Seal(Blue).
(9) Press
A part installed using a press or driver, such as a journal, should first be coated with oil on its outer or inner
circumference so that it will go into place smoothly.
(10) Ball Bearing
When installing a ball bearing, the bearing race which is affected by friction should be pushed by a suitable driver.
This prevents severe stress on the balls and races, and prevents races and balls from being dented. Press a ball
bearing until it stops at the stop in the hole or on the shaft.
(11) Oil Seal, Grease Seal
Replace any oil or grease seals that were removed with new ones, as removal generally damages seals.
When pressing in a seal which has manufacturers marks, press it in with the marks facing out. Seals should be
pressed into place using a suitable driver, which contacts evenly with the side of seal, until the face of the seal is even
with the end of the hole.
(12) Seal Guide
A seal guide is required for certain oil or grease seals during installation to avoid damage to the seal lips. Before
a shaft passes through a seal, apply a little oil, preferably high temperature grease on the lips to reduce rubber to
metal friction.
(13) Circlip, Retaining Ring
Replace any circlips and retaining rings that were removed with new ones, as removal weakens and deforms them.
When installing circlips and retaining rings, take care to compress or expand them only enough to install them and
no more.
(14) Cotter Pin
Replace any cotter pins that were removed with new ones, as removal deforms and breaks them.

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GENERAL INFORMATION 1-3
Before Servicing
(15) Lubrication
Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have
an adequate lubricative film. During assembly, oil or grease(whichever is more suitable) should be applied to any
rubbing surface which has lost its lubricative film. Old grease and dirty oil should be cleaned off. Deteriorated grease
has lost its lubricative quality and may contain abrasive foreign particles.
Dont use just any oil or grease. Some oils and greases in particular should be used only in certain applications and
may be harmful if used in an application for which they are not intended. This manual makes reference to molybdenum
disulfide grease(MoS2)in the assembly of certain engine parts. Always check manufacturer recommendations before
using such special lubricants.
(16) Replacement Parts
When there is a replacement instruction, replace these parts with new ones every time they are removed. There
replacement parts will be damaged or lose their original function once removed.
(17) Inspection
When parts have been disassembled, visually inspect these parts for the following conditions or other damage. If
there is any doubt as to the condition of them, replace them with new ones.
Abrasion
Bent
Color change

Crack
Dent
Deterioration

Hardening
Scratch
Seizure

Warp
Wear

(18) Specifications
Specification terms are defined as follows:
"Standards": show dimensions or performances which brand-new parts or systems have.
"Service Limits" indicate the usable limits. If the measurement shows excessive wear or deteriorated performance,
replace the damaged parts.

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1-4 GENERAL INFORMATION
General Specifications
Model
Dimension

TH23D

2
2 Height)

Overall (Length
Width

Weight*
Engine

mm

160.22202.52223

(in)

(6.3

kg (lbs)
Type

2 8.0 2 8.8)

160.2
(6.3

2.1 (4.6)

2 205 2 223
2 8.0 2 8.8)

2.2 (4.8)

TH34D

173
(6.8

2 224 2 249
2 8.8 2 9.8)
2.7 (6.0)

Forced air cooled 2-stroke single cylinder gasoline engine

Diplacement

ml(cu in)

Bore

mm

2 stroke

(in)

22.5 (1.37)

2 28
(1.26 2 1.10)
32

Direction of rotation

25.4 (1.55)

2 28
(1.34 2 1.10)
34

2 31
(1.46 2 1.22)
37

Diaphragm type

Ignition type

Solid state ignition

Spark plug

NGK BPMR6A

Starting

Recoil starter

Cluch type mm
Clutch drum bore

33.3 (2.03)

Counterclockwise, viewed from PTO side

Carburetor

Fuel

TH26D

Automatic centrifugal type

54 or 56

mm

78

Air cleaner

Dry type (Polyurethane form element)

Mixing ratio

Regular unleaded gasoline 50:1 2-stroke engine oil (JASO-FC

class)

Tank capacity

0.5

0.6

* : The unit without the throttle cable and lever.

Specifications are subject to change without notice.

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GENERAL INFORMATION 1-5
Idling Speed
Idling Speed Adjustment

case that the cutting head or the cutting blade is installed with a
Adrive
shaft in the engine, the idling speed adjustment should proceed
as follows:

Start the engine and leave it running at idling speed to warm it up

thoroughly.
the engine stops while idling, turn the throttle stop screw[A]
clockwise until the cutting head or the cutting blade begins to rotate.
Then back off one half turn. The cutting head or the cutting blade
must not rotate.
If the cutting head or the cutting blade rotates when the engine Is
idling, turn the throttle stop screw counterclockwise until the cutting
head or the cutting blade stops rotating and then turn the throttle stop
screw another one half turn.

If

Idling speed-TH23D/TH26D/TH34D
3000200 rpm

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1-6 GENERAL INFORMATION
Periodic Maintenance Chart

Accidental engine starting can cause injury.

Always remove the spark plug cap before servicing the engine to prevent accidental starting.

Interval
Maintenance
Daily

First

Every

Every

Every

20 hours

20 hours

50 hours

100 hours

Check and replenish fuel

Check for fuel leakage
Check bolts, nuts and screws for looseness and loss
Check engine switch operation
Clean fuel filter
* Clean air filter element

Tighten bolts, nuts and screws

Clean spark plug and adjust electorode gap

* Remove dust and dirt from cylinder fins

K Remove carbon deposits on piston head and inside cylinder
K Remove carbon deposits in the muffler
K Clean net of spark arrester
K Check the sliding portion of crankshaft, connectiong rod etc.
Fuel tube

It is recommecded to replace every 3 years.

NOTE

The service intervals indicated are to be used as a guide. * Service to be performed more frequently as
necessary by operating condition.

K : These items must be performed with proper tools. See your authorized Kawasaki dealer for service.

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GENERAL INFORMATION 1-7
Tightening Torque
The following tables list the tightening torque for the major fasteners and the parts requiring use of a non-permanent
locking agent or requid gasket.
Letters used in the following "Tightening Torque" table mean.
LA: Apply a non-permanent locking agent to the threads.
LG: Apply a liquid gasket to the sealing surfaces.
MTGS:Mounting screw(s)

Tightening Torque - TH23D/TH26D/TH34D

Torque
Size

N1m

kg1m

ft1lb

Air Cleaner Cap MTGS

Fasteners

M5

2.0 2.5

0.20 0.25

1.4 1.8

Ignition Coil MTGS

M4

2.0 2.5

0.20 0.25

1.4 1.8

LA

Recoil Starter MTGS

M4

1.7 2.0

0.17 0.20

1.2 1.4

LA

Crankcase Connecting Screw

M5

3.5 4.0

0.35 0.40

2.5 3

LG, LA

Engine Shroud MTGS

M5

3.5 4.0

0.35 0.40

2.5 3

LA

Carburetor/Air Cleaner Case MTG

M5

3.5 4.0

0.35 0.40

2.5 3

Insulator MTGS

M5

3.5 4.0

0.35 0.40

2.5 3

LA

Fuel Tank MTGS (Crankcase side)

M5

3.5 4.0

0.35 0.40

2.5 3

LA

Fuel Tank MTGS (Recoil Starter side)

M5

2.0 - 2.5

0.20 - 0.25

1.4 - 1.8

LA

Muffler MTGS

M5

3.5 4.0

0.35 0.40

2.5 3

LA

Muffler Cover MTGS

M5

3.5 4.0

0.35 0.40

2.5 3

LA

Cylinder MTGS

Remarks

M5

3.5 4.0

0.35 0.40

2.5 3

LA

TH23D, TH26D

M6

8 - 10

0.8 - 1.0

5.8 - 7.2

LA

TH34D

M8

14 - 16

1.4 - 1.6

10 - 12

LA

TH23D, TH26D

M6

8 10

0.8 1.0

5.8 7.2

TH34D

M8

14 16

1.4 1.6

10 12

M8

14 16

1.4 1.6

10 12

Starter Pulley

M8

10 12

1.0 1.2

7.2 8.7

Spark plug

M14

12 17

1.2 1.7

8.7 12.3

Clutch Pin
Flywheel Nut
Starter Pulley Nut

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1-8 GENERAL INFORMATION
Clearance Table
Clearance Table

Unit : mm(in)
Service Limit

Cylinder bore

TH23D

TH26D

TH34D

32.1

34.1

37.1

(1.263)

(1.342)

(1.461)

Remarks
Replace if over

Piston-to-cylinder clearance

0.15

Replace if over

Piston ring-to-groove clearance

0.17

Replace if over

Piston ring end-gap

0.7

Replace if over

Piston-to-piston pin clearance

0.1

Replace if over

Connecting rod big-end axial play

0.5

Replace if over

Connecting rod big-end radial play

0.15

Replace if over

Piston pin-to-needle bearing radial play

0.15

Replace if over

Ball bearing axial play

0.5

Replace if over

Crankshaft axial play

0.05 ~ 0.295

Adjust if over

*does not include that of ball bearings.

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GENERAL INFORMATION 1-9
Setting Table
Setting Table
Standard Setting
TH23D
The engine speed at which the clutch engages

TH26D

TH34D

#37.5

#37.5

about 4000 rpm at

0.4 kg1cm of drag torque
0.3 to 0.5 mm
(0.011 to 0.019 in.)

Ignition coil air-gap

Ignition timing

25 B.T.D.C.@ 7000 rpm

Main jet

Carburetor
Idle Needle Pin*

# 34
1.0 1/4 turn open
(other than US and CN)

* : The adjustment of idle needle pins of the TH23D/TH26D/TH34D models destined for US and Canada are
impossible for tampering prevention.

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REMOVAL/INSTALLATION 2-1

Removal/Installation
Table of Contents
Clutch and Fuel Tank ......................................................................................................................................................... 2-2
Removal.......................................................................................................................................................................2-2
Installation....................................................................................................................................................................2-2
Fuel Filter Cleaning.....................................................................................................................................................2-3
Air Cleaner, Carburetor, and Muffler..................................................................................................................................2-4
Removal.......................................................................................................................................................................2-4
Installation....................................................................................................................................................................2-5
Air Cleaner Element Cleaning.....................................................................................................................................2-5
Spark Arrester Cleaning..............................................................................................................................................2-5
Recoil Starter, Shroud, Fan Housing, and Ignition Coil.....................................................................................................2-6
Removal.......................................................................................................................................................................2-6
Installation....................................................................................................................................................................2-6
Ignition Coil Inspection................................................................................................................................................2-7
Flywheel and Cylinder........................................................................................................................................................2-8
Removal.......................................................................................................................................................................2-8
Installation....................................................................................................................................................................2-9
Piston and Piston Ring.....................................................................................................................................................2-10
Removal.....................................................................................................................................................................2-10
Installation..................................................................................................................................................................2-10
Crankcase and Crankshaft...............................................................................................................................................2-11
Removal.....................................................................................................................................................................2-11
Installation..................................................................................................................................................................2-11
Crankshaft Shim Selection........................................................................................................................................2-12
Crankshaft Shim Installation......................................................................................................................................2-12

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2-2 REMOVAL/INSTALLATION
Clutch and Fuel Tank
Removal

the clutch shoes [A] from turning by using a pair of pliers,

Keeping
release the clutch pins [B] by turning counterclockwise to remove the
clutch assembly.

Take care not to scratch the clutch shoes [A].

Do not remove the clutch spring [C] if not needed.

the stand [A] and unscrew the remaining mounting screw [B]
Remove
of the fuel tank.
Loosen the fuel tube clamps to remove the fuel tank [C] together.

Remove the tank grommet [A] out of the fuel tank.

Installation

is the reverse of removal.

Installation
Fix
the
fuel
filter to the delivery side opaque tube and clamp it.
Put the opaque
tube into the fuel tank together with the fuel filter and
fit the tank grommet
into its hole in order that the raised letters on the
tank grommet can look toward outside.

NOTE

Apply a bit of 2-stroke engine oil to the grommet in order to make

the insertion easy.

Install the tank grommet [A] to the fuel tank so that the transparent
tube [B] comes toward the fuel tank center.

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REMOVAL/INSTALLATION 2-3
Clutch and Fuel Tank
locking agent to screw threads of the clutch pins.
Apply
a bit of heat resisting grease to the clutch-pin holes.
Apply
Put
the
shoes and the plate on the flywheel with raised letter
such as clutch
R54 toward you to install them by tightening the clutch pins
to the specified torque.
Specified Clutch Pin Tightening Torque
TH23D/TH26D:
8~10 N1m (0.8~1.0 kg1m, 5.8~7.2 ft1lb)
TH34D:

14~16 N1m (1.4~1.6 kg1m, 10~12 ft1lb)

the clutch spring to the clutch shoes before installing the clutch
Install
shoes on the flywheel if the clutch spring is removed.

Fuel Filter Cleaning

the fuel filter assembly together with the grommet [A] from
Remove
the fuel tank [B] to keep dust from entering the fuel filter [C].
the fuel filter in a bath of high flash-point solvent.
Clean
Dry the fuel filter before installing.

NOTE

If fuel does not flow better with the fuel filter cleaned, replace the
fuel filter with new one.

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2-4 REMOVAL/INSTALLATION
Air Cleaner, Carburetor, and Muffler
Removal

out the plug cap [A].

Pull
Remove
cover [B].
Unscrew the
the
shroud mounting screws [C] to remove the shroud [D].

the air cleaner mounting screws [A] to remove the air cleaner
Unscrew
cap [B].

the two carburetor mounting screws [A] to remove the

Unscrew
carburetor [B] together with the gasket.

NOTE

Do not remove the carburetor if not needed.

the two insulator mounting screws [A] to remove the insulator

Unscrew
[B] together with the gasket [C].

the two flange bolts [A] to remove the muffler body complete
Unscrew
[B] together with the gasket [C].

NOTE

In ordinary circumstances, there is no need to remove the muffler

body complete out of the cylinder.

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REMOVAL/INSTALLATION 2-5
Air Cleaner, Carburetor, and Muffler
Installation

is the reverse of removal.

Installation
Use
new
gaskets.

insulator [A] is removed, fit the screw to round seat and nuts [B]
Iftothe
the hexagonal seats in the insulator, and put the insulator gasket

[C] onto screw ends, then install the insulator on the cylinder [D] with
the screws.
Each pulse hole [E] must align.

Air Cleaner Element Cleaning

the air cleaner element in a bath of high flash-point solvent.

Clean
Dry the element before installing.

CAUTION
More frequent maintenance is necessary when the engine is
operated in dusty condition.

Spark Arrester Cleaning

Hot engine parts can cause severe burns. Allow engine to stop
and cool before servicing spark arrester.
the shroud.
Remove
the spark arrester by unscrewing the screw at the exhaust
Remove
pipe in the muffler.
deposits from the spark arrester screen by brushing it.
Clean
Install the spark arrester and the shroud.

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2-6 REMOVAL/INSTALLATION
Recoil Starter, Shroud, Fan Housing, and Ignition Coil
Removal

Remove the mounting screws [A] to remove the recoil starter [B].

the starting pulley lock nut [A] counterclockwise to remove it

Release
together with the washer [B].
Remove the starting pulley [C] by turning itself counterclockwise.

the spark plug cap [A] out of the spark plug.

Remove
Remove
cover [B].
Remove the
the shroud [C].

the ignition lead wire [A].

Disconnect
Unscrew
the
housing [C]. fan housing mounting screws [B] to remove the fan
the ignition coil mounting bolts [D] to remove the ignition coil
Unscrew
[E] together with the insulators.

Installation

is the reverse of removal.

Installation
Adjust
the
ignition
coil air gap to the specified value.

Ignition Coil Air Gap Specified TH23D/TH26D/TH34D

0.3 to 0.5 mm (0.011 to 0.019 in.)

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REMOVAL/INSTALLATION 2-7
Recoil Starter, Shroud, Fan Housing, and Ignition Coil
the starting pulley to the crankshaft by turning clockwise.
Install
The recoil pawl must be fitted on the pulley as shown.

Ignition Coil Inspection

The ignition coil has been integrated with an igniter being solid-state.
Use the Kawasaki hand tester(P/N 57001-1394); resistance value
may vary with individual meters.
Set the Kawasaki hand tester to the specified range.
Connect the test leads to the points shown and read the resistance.
If the resistance is not as specified, replace the ignition coil.
If the meter reads as specified, the ignition coil windings probably
good. However if the ignition system still does not perform as it
should after all other components have been checked, replace the
ignition coil with one known to be good.
Ignition Coil Specified Resistance
Resistance Between
[B] and [C]
Primary Winding

TH23D/TH26D
TH34D

0.8
to 1.2
(Rx1

)
0.4
to 0.6
(Rx1
)

[A] and [C]

Secondary Winding
9k
to15k
(Rx1k
)
8k
to13k
(Rx1k
)

NOTE

It is unable to inspect the igniter whether it is good or bad with the

Kawasaki hand tester since it was integrated with the ignition coil.

Whenever you have doubt as to function of the igniter to operate,

try replacing the ignition coil with one known to be good.

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2-8 REMOVAL/INSTALLATION
Flywheel and Cylinder
Removal

the flywheel nut [A] counterclockwise to remove it.

Release
Remove
as shown.the flywheel [G] out of the crankshaft by using a puller [H]
the key [C] from the crankshaft.
Remove
Unscrew
the flange bolts [D] to remove the cylinder [E] and the
cylinder gasket
[F] from the crankcase.

to see if the pulse hole [A] under the inlet port [B] is clogged.
Check
If clogged, clean.

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REMOVAL/INSTALLATION 2-9
Flywheel and Cylinder
Installation

is the reverse of removal.

Installation
Use
a
new
gasket.
Set the cylinder
gasket noting its profile [A] for scavenging ports.

the carbon deposits inside the cylinder, especially slit [A] for
Scrape
decompression, with a suitable tool.

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2-10 REMOVAL/INSTALLATION
Piston and Piston Ring
Removal
CAUTION
Do not reuse snap rings as removal weakens and deforms
them. They could fall out and score the cylinder wall.
snap rings [A] out of the piston [B].
Remove
Pull
the
piston
pin [C] off the piston [B] to remove the piston [B] and
the needle bearing
[D] out of small-end of the connecting rod [E].
Remove
piston
rings
[F] out of the piston [B].

Installation

is the reverse of removal.

Installation
the piston rings [A] in order that the radii at the ring gap can
Position
meet at the piston ring stopper pin [B] in the piston groove when the
rings are compressed.

the needle bearing into small end of the connecting rod to install
Fit
the piston to small end of the connecting rod, with the mark [A] on
piston crown pointing to specified side, with the piston pin.

"H mark" [A] on piston crown should face muffler side.

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REMOVAL/INSTALLATION 2-11
Crankcase and Crankshaft
Removal

the tightening screws [A] to split the crankcase [B] from the
Unscrew
crankcases [C].

Lightly tap the crankcase with a plastic hammer to split it.

Take care not to damage the oil seals.
Take care not to lose the adjusting shims [D]. (0 to 1 piece).

Installation
The crankshaft, the connecting rod, and the needle bearing are
inseparable. This means that the crankshaft must always be replaced as
a complete unit in the event of damage to any one of these parts when
fitting a replacement always install new ball bearings. The complete
crankcase must be replaced if either half is damaged.
Installation is the reverse of removal.
Apply fine oil to both ball bearings.
Apply heat resisting grease between oil seal lips.
If the original crankcase is reused, remove liquid must be cleaned
thoroughly to ensure a perfect seal.
Sparingly apply liquid gasket on the sealing surface of the starter half
of the crankcase.

CAUTION
Excessive amounts may block something inside and cause
serious damage.
the flywheel half of the crankcase onto the starter half of the
Put
crankcase so that the dowel pins can be fit into their holes of the
flywheel half of the crankcase and tighten the bolts to the specified
torque evenly in the order shown(see Tightening Torque).

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2-12 REMOVAL/INSTALLATION
Crankcase and Crankshaft
Crankshaft Shim Selection
Whenever any one of the crankshaft, the crankcase, and the ball
bearing is replaced; select the crankshaft shim(s) to adjust crankshaft
axial play according to crankshaft shim selection.
Measure dimension of A, B, and C shown in the figure and calculate
crankshaft clearance(dimension D) by the following equation.
D=A+B- C

NOTE

Measure dimension of A and B at the outer race not to allow ball

bearing axial play to affect the shim selection.
TH23D/TH26D/TH34D
Shim thickness

Shim Parts No.

mm (in.)

TH23D/TH26D

TH34D

0.2 (0.007)

92025-2125

92025 - 2104

0 4 (0.015)

92025-2126

92025 - 2105

0.6 (0.023)

92025-2127

92025 - 2106

TH23D/TH26D/TH34D
Clearance
(dimension D) mm

Fitting shim
TH23D, TH26D

0.05~0.27

TH34D

None

0.28~0.47

92025-2125

92025-2104

0.48~0.67

92025-2126

92025-2105

0.68~0.79

92025-2127

92025-2106

Crankshaft Shim Installation

shim(s) [A] selected

Install
assemble the crankcase.

onto the crankshaft as shown and

Crankshaft Axial Play TH23D/TH26D/TH34D

Standard: 0.05~0.295 mm (0.001~0.011 in.)*

*does not include that of ball bearings.

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TROUBLESHOOTING 3-1

Troubleshooting
Table of Contents
Engine Troubleshooting......................................................................................................................................................3-2
Hard Starting...................................................................................................................................................................3-2
Engine Malfunction at Low Speed..................................................................................................................................3-4
Engine Malfunction at High Speed.................................................................................................................................3-4
Insufficient Power............................................................................................................................................................3-4
Abnormal Engine Noises................................................................................................................................................3-5
Hunting............................................................................................................................................................................3-5
Fuel Leakage from Carburetor........................................................................................................................................3-5
Excessive Fuel Consumption..........................................................................................................................................3-5
Engine Stops during Operation ...................................................................................................................................... 3-6

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3-2 TROUBLESHOOTING
Engine Troubleshooting
Hard Starting
Symptom
Pulling recoil starter handle
would not cause sufficient
compression.

After choking and making

several starting attempts, it is
found, on removing spark
plug, that electrodes are still
dry.

After choking and making

several starting attempts, it is
found, on removing spark
plug, that electrodes are
excessively wet.

Poor compression

Insufficient fuel

Excess fuel

Cause
Wear in piston
Wear in piston ring
Stick of piston ring
Wear or deformation of
cylider bore.
Poor tightening of cylinder and
spark plug
No fuel in fuel tank
Clogging of dust or entry of air
in fuel pipe
Clogged fuel tank cap air vent
and breather
Foul fuel filter in fuel tank
Poor opening and closing of
choke valve
Air entering at gasket fitted to
carburetor flange
Clogged carburetor needle jet
or main jet
Faulty choking(ln summer, or
when engine is warm, full
choking gives too rich mixture)
Overflow of fuel from
carburetor
Clogged air cleaner

On removing spark plug,

moisture condensed on spark
plug electrodes.

Make spark check.

No spark but spark appears on
spark plug replaced.

No spark in any spark plug,

but spark appears when the
end of high tension cord is
touched to engine block.

Faulty fuel

Faulty spark plug

Faulty plug cap

Mixture of water into fuel

Deterioration in fuel because of
poor long-term storage
Use of fuel other than
designated
Electrodes are burned and
damaged to cause too wide
gap
Much carbon bridging
electrodes gap
Small foreign matter being
caught between electrodes
Faulty insulation of electrodes
Looseness of terminal
(Provided that only spare parts)
Faulty contacting at spark plug
cap

Remedy
Replace
Replace
Clean ring groove
and replace piston ring
Replace cylinder and
piston ring as a set
Tighten
Replenish
Clean
Clean
Clean
Correct
Tighten or replace gasket
Clean
Remove spark plug,
with engine switch OFF,
exhaust excess fuel by
pulling starter rope
Check carburetor and
exhaust excess fuel from
cylinder
Clean air cleaner and
exhaust excess fuel from
cylinder
Change fuel
Change fuel
Change fuel
Crrect gap or replace

Clean or replace
Clean
Clean or replace spark
plug
Tighten securely
Remove plug cap and
connect terminal again

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TROUBLESHOOTING 3-3
Engine Troubleshooting
Symptom

Cause

No

Spark appears when stop

Faulty stop switch

spark

switch wire is

or

disconnected at

very

connector.

week

No spark appears even

Slow recoil starter

spark

when stop switch wire is

revolution

at the

disconnected at

end

connector.

of

Spark appears when

high

ignition coil is replaced

ten-

with new one.

sion

Spark appears when

on

flywheel is replaced with

cord

new one.

Stop switch lead wire is

Remedy
Correct

jammed
Short circuit in stop switch

Replace

Recoil starter revolution is

Pull recoil starter rope

lower than that igniter begins to

more rapidly

work.
Faulty ignition coil

Wiring of coil coming short-

Replace

circuited or disconnect
Faulty flywheel

Stop lead wire is jammed

Correct or replace

Flywheel demagnetized

Replace

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3-4 TROUBLESHOOTING
Engine Troubleshooting
Engine Malfunction at Low Speed
Symptom

Cause

Remedy

When throttle value is opened

Faulty carburetor

Clogging in carburetor inside

Disassemble and clean

gradually, revolution speed

Faulty fuel filter

Foul fuel filter

Clean or replace

drops at some position or

Air enters at

Faulty carburetor gasket

Replace

Incomplete fitting of carburetor

Tighten

Faulty insulation of spark plug

Replace

engine stops.
When spark test of spark plug
is made with recoil starter rope

carburetor flange
Faulty ignition

Foul electrodes

Clean

pulled, spark appears very

system

Faulty magneto

Replace

week.

Faulty ignition coil

Engine Malfunction at High Speed

Symptom

Cause

Same as "Engine Malfunction

Faulty carburetor

at Low Speed" mentioned

Faulty fuel filter

above.

Faulty ignition

Same as "Engine Malfunction

at Low Speed"

Remedy
Same as "Engine
Malfunction at Low
Speed"

system
Loaded operation causes

Clogged fuel tank cap air vent and breather

Clean

revolution fluctuation with big

Dust clogging in or entry of air into fuel pipe or

Clean

frequency.

carburetor

Insufficient Power
Symptom
Same as "Hard Starting"

Cause
Poor compression

Same as "Hard Starting"

Remedy
Same as "Hard Starting"

Insufficient fuel
Excess fuel
Faulty fuel
Faulty magneto
Faulty igniter
Engine overheated

Clogged air cleaner

Clean

Carbon deposit inside combustion chamber

Clean

Inappropriate mixing ratio(too little oil)

Change fuel

Broken cooling fan blade

Replace

Dirt or dust attached to cooling fins of cylinder

Clean

Grass or dirt attached to cooling air passage and

Clean

flywheel blade
Thick smoke issues from

Excess fuel

Same as "Hard Starting"

Same as "Hard Starting"

exhaust port.

Faulty exhaust

Carbon deposit narrows

Clean

system

exhaust passage and muffler

Excessive oil mixed

Engine knocking

Inferior fuel

Change fuel
Change fuel

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TROUBLESHOOTING 3-5
Engine Troubleshooting
Abnormal Engine Noises
Symptom

Cause

Piston Slapping

Remedy

Cylinder and piston ring wear

Replace

Wear and/or deformation in piston

Replace

Carbon deposit inside combustion chamber

Clean

Wear in piston pin and connecting rod small end

Replace

bearing
Connecting rod noise

Wear in piston and piston pin

Replace

Wear in large and small end bearings

Replace (Crankshaft Assy)

Hunting
Symptom

Cause

Hunting

Remedy

Foul air cleaner

Clean

Dust clogging in or air entry into fuel pipe

Clean

Clogged fuel tank cap air vent and breather

Clean

Clogged carburetor

Clean

Fuel Leakage from Carburetor

Symptom

Cause

Fuel leak from carburetor

Foreign matter attached to needle valve and/or valve

Remedy
Clean

seat
Correction or wear in needle valve and/or valve seat

Replace needle valve

assembly

Poor tightening of diaphragm gasket

Tighten or replace

Excessive Fuel Consumption

Symptom

Cause

Same as "Hard Starting"

Poor compression

Sufficient compression but

Too rich fuel mixture

Adjust

excessive fuel consumption.

Inferior fuel

Replace

Foul air cleaner

Clean

Too high idling speed

Adjust

Choke valve not fully open

Adjust

Same as "Fuel Leakage from

Same as "Fuel

Same as "Fuel Leakage

from Carburetor"

Same as "Hard Starting"

Remedy

Carburetor"

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Same as "Hard Starting"

Leakage from Carburetor"

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3-6 TROUBLESHOOTING
Engine Troubleshooting
Engine Stops during Operation
Symptom
Difficulty in cranking, or

Cause
Overheat

seizure

Excessively lean fuel

Remedy
Adjust carburetor

mixture(too little fuel)

Inferior lubricating oil mixed

Change fuel

Excessive carbon deposit in

Clean

conbusion chamber
Dust accumulation on cooling

Clean

fins of cylinder
Cranking is easy

Faulty electrical

Faulty spark plug

Clean or replace

system

Faulty magneto

Replace

Looseness in connections

Check and repair

Faulty ignition coil

Replace

Clogged fuel line

Clean

Foul air cleaner

Clean or replace

Fuel in tank used up

Replenish

Dust clogging in fuel passage

Clean

Faulty fuel system

Faulty carburetor

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SUPPLEMENT 4-1

Supplement
Table of Contents
Rotary Valve, Diaphragm Type Carburetor........................................................................................................................ 4-2
Priming Pump System.................................................................................................................................................4-2
Fuel Pump System......................................................................................................................................................4-2
Metering Chamber System..........................................................................................................................................4-3
Disassembly ................................................................................................................................................................ 4-4
Reassembly.................................................................................................................................................................4-4
Inspection and Adjustment..........................................................................................................................................4-5
Idle Needle Pin Adjustment.........................................................................................................................................4-6
Rotary Valve, Diaphragm Type Carburetor Troubleshooting..............................................................................................4-7

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4-2 SUPPLEMENT
Rotary Valve, Diaphragm Type Carburetor

1. Engine Pulse Passage

12. Valve Spring

2. Fuel Pump Diaphragm

13. Metering Chamber

3. Fuel Inlet

14. Lead Cam

4. Inlet Check Valve

15. Idle Needle Pin

5. Outlet Check Valve

16. Main Jet

6. Inlet Screen

17. Main Nozzle

7. Needle Valve

18. Priming Pump

8. Throttle Valve

19. Main Check Valve

9. Air Vent

20. Priming Pump Check Valve

10. Main Diaphragm

21. Overflow Pipe

11. Control Level

22. Idle Adjust Screw

Priming Pump System

When starting the engine, by pushing the priming pump, air is pushed
out toward the overflow pipe from the priming pump check valve, which
causes negative pressure inside the metering chamber and the needle
valve opens.
Then fuel from the fuel tanks is sucked into the metering chamber
through the inlet check valve and then into the priming pump.
And excessive fuel is discharged from the overflow pipe. This operation
is called Priming operation at starting.

Fuel Pump System

After starting the engine, part of pressure change inside the
crankcase caused by engine revolution is transmitted to the pump
diaphragm through the engine pulse passage, which deforms the pump
diaphragm and it starts reciprocationg motion. Namely, fuel is sucked
from the tank into the carburetor under pressure by volume change
due to the pump diaphragms reciprocating motion and the inlet and
the outlet check valves function.

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SUPPLEMENT 4-3
Rotary Valve, Diaphragm Type Carburetor

1. Engine Pulse Passage

12. Valve Spring

2. Fuel Pump Diaphragm

13. Metering Chamber

3. Fuel Inlet

14. Lead Cam

4. Inlet Check Valve

15. Idle Needle Pin

5. Outlet Check Valve

16. Main Jet

6. Inlet Screen

17. Main Nozzle

7. Needle Valve

18. Priming Pump

8. Throttle Valve

19. Main Check Valve

9. Air Vent

20. Priming Pump Check Valve

10. Main Diaphragm

21. Overflow Pipe

11. Control Level

22. Idle Adjust Screw

Metering Chamber System

The main diaphragm forming the metering chamber senses inside fuel
pressure change of the metering chamber, which occurs in accordance
with the engine revolution change, as vertical motion. And it works to
keep a uniform pressure (equivalent to the fuel surface of a float type
carburetor) inside the metering chamber by opening and closing the
needle valve.
Fuel in the metering chamber is drawn by negative pressure in the
venturi, blown out from the main nozzle, mixed with air passed through
the venturi and sucked into the engine. When the engine stops, negative
pressure in the venturi becomes zero; the control lever is pushed up with
the valve spring; and the needle valve closes. Then fuel flow stops and
overflow is prevented.

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4-4 SUPPLEMENT
Rotary Valve, Diaphragm Type Carburetor
1. Inlet Screen
2. Pump Body
3. Valve Spring
4. Lever Pin
5. Control Lever
6. Gasket
7. Main Diaphragm
8. Air Purge Body
9. Priming Pump
10. Priming Pump Cover
11. Pump Cover Screw
12. Throttle Collar Screw
13. Idle Adjust Screw
14. Throttle Valve Assembly
15. Carburetor Body
16. Oring
17. Main Jet
18. Pump Gasket
19. Pump Diaphragm
20. Lever Pin Screw
21. Needle Valve

Disassembly
Before disassembling, clean the carburetor with a high flash-point
solvent so that no dirt enters the carburetor.
Remove 2 throttle-collar screws to remove the throttle valve assembly
from the carburetor body.

CAUTION
Do not disassemble the throttle valve assembly.
4 pump-cover screws with the priming pump side upward.
Remove
Remove
pump cover, the priming pump the air purge
body, thethemainpriming
diaphragm, the gasket, the pump body, the pump

diaphragm, and the pump gasket in that order.

Remove the main jet and the O-ring from the carburetor body.

CAUTION
Do not remove the main nozzle as it is press fitted.
If much dirt is found inside the carburetor, especially on the
inlet screen, clean the fuel tank inside and replace the fuel
filter.

Reassembly
Before reassembly, clean removed parts and the body with suitable
detergent and use compressed air to dry.
Reasembly is the reverse of removal.

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SUPPLEMENT 4-5
Rotary Valve, Diaphragm Type Carburetor
Inspection and Adjustment

the carburetor with a high flash-point solvent and apply air.

Clean
Check
see that no dirt or corrosion is found in the main jet.
If dirt istofound,
clean and apply air.
If corrosion is found, replace the main jet with new one.

CAUTION
When replacing the main jet, be sure to replace with a jet with
the same number.
to the gaskets, check to see if no deformation or damage is found.
As
If deformation or damage is found, replace them with new ones.
the pump diaphram to see if no damage or hardening is found.
Check
Check the inlet check valve and the outlet check valve in particular

and make sure that they are flat and not bent.
If they are bent, replace them with new ones.
Check the main diaphragm to see if there is any peeling, damage or
the aluminum plate bent.
If they are bent, replace with new one. After cleaning the pump body,
check to see that the control lever functions well and that no dirt is
found on the inlet screen.

CAUTION
To prevent deformation or sticking of the main check valve,
never apply high pressure air to the valve.
to see that there is no deformation or damage on the check
Check
valve.

If any, replace it with new one.

Check to see that no hole, damage or abnormal hardening is present
on the priming pump.
If present, replace it with new one.
Push the tip end of the control lever lightly and make sure that the
lever moves smoothly.
If the needle valve which opens and closes with movement of the
control lever, has got some damage on its tip end or wear due to its
long use, applying air to the tip end of the needle valve will not be
solution for overflow.
In this case, replace the pump body assembly with new one.

the control lever [A] so as to be at the same level as the bottom

Adjust
[B] of the metering chamber as shown.
If correction is necessary, bend the lever lightly to be on the same
surface of the metering chamber bottom, or adjust the lever to be
from 1.4 mm (0.055 in.) to 1.6 mm (0.062 in.) [C] with surface of the
pump body as standard.

check function of the main check valve, stick vinyl pipe end to the
To
main check valve and breathe in and out from the other end.

If the valve opens when breathing in and closes when breathing out,
the valve functions well.
If any problems are found, soak the valve in gasoline for about 10
minutes and repeat breathing in and out several times.
If no improvement shows, replace the pump body with new one.

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4-6 SUPPLEMENT
Rotary Valve, Diaphragm Type Carburetor
Idle Needle Pin Adjustment

the engine and move the throttle lever to its fully-closed position.
Start
Raise the engine speed just before the cutting tool begins turning by
turning the idle adjust screw clockwise.

the idle needle pin where the engine speed rises highest by
Adjust
turning it clockwise or counterclockwise. When the engine speed

rises and the cutting tool begins turning, lower the engine speed
by turning the idle adjust screw counterclockwise and readjust the
idle needle pin where the engine speed rises highest right before
the cutting tool begins turning by turning the pin clockwise or
counterclockwise.
When the idle needle pin position is fixed, turn the idle needle pin
counterclockwise1/4 to 1/2 turn more and stop turning.
And then adjust the idle adjust screw to the specified speed. See
Setting Table.

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SUPPLEMENT 4-7
Rotary Valve, Diaphragm Type Carburetor Troubleshooting
Symptom

Cause

Engine hard to start

Overflow, fuel leakage

Priming is hard to suck fuel

Engine would not idle

Idling is too slow

Remedy

Idle Needle pin maladjustment

Adjust

Idle adjust screw maladjustment

Adjust

Foul fuel filter in fuel tank

Clean

Clogging in fuel passage

Clean

Air leakage in fuel passage

Repair

Improper fuel

Change

Inferior check valve

Replace

Clogged air cleaner element

Clean or replace

Damaged carburetor control (metering) lever

Repair

Malfunction of carburetor control (metering) lever

Repair

Inferior main diaphragm gasket

Replace

Poor tightening of main diaphragm cover screw

Tighten

Damaged main diaphragm

Replace

Adherence of inlet needle valve

Replace

Inlet needle valve wear

Replace

Inlet needle valve sticking

Repair

Poor tightening of fuel pump cover screw

Tighten

Damaged carburetor control (metering) lever

Repair

Too high carburetor control (metering) lever

Adjust

Malfunction of carburetor control (metering) lever

Repair

Deformed carburetor control (metering) lever spring

Replace

Inferior main diaphragm gasket

Replace

Poor tightening of main diaphragm cover screw

Tighten

Damaged main diaphragm

Replace

Inlet needle valve wear

Replace

Inlet needle valve sticking

Repair

Clogged fuel tank cap air vent

Clean

Foul fuel filter in fuel tank

Clean

Clogged fuel line

Clean

Air leakage in fuel line

Repair

Damaged priming pump

Replace

Inferior priming pump check valve

Replace

Malfunction of carburetor control (metering) lever

Repair

Inferior main diaphragm gasket

Replace

Poor tightening of main diaphragm cover screw

Tighten

Damaged main diaphragm

Replace

Adherence of inlet needle valve

Replace

Idle needle pin maladjustment

Adjust

Idle adjust screw maladjustment

Adjust

Foul fuel filter in fuel tank

Clean

Air leakage in fuel line

Repair

Inferior manifold o-ring

Replace

Poor tightening of carburetor

Tighten

Idle needle pin maladjustment

Adjust

Clogged air cleaner element

Clean or replace

Damaged carburetor control (metering) lever

Replace

Carburetor control (metering) lever is too high

Adjust

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4-8 SUPPLEMENT
Rotary Valve, Diaphragm Type Carburetor Troubleshooting
Symptom

Idling is unstable

Idling does not continue

Engine does not accelerate

Cause

Remedy

Malfunction of carburetor control (metering) lever

Replace

Inlet needle valve wear

Replace

Foreign matter sticking of needle valve

Clean

Idle needle pin maladjustment

Adjust

Idle adjust screw maladjustment

Adjust

Clogged fuel tank cap air vent

Clean

Foul fuel filter in fuel tank

Clean

Clogged fuel line

Clean

Air leakage in fuel line

Repair

Improper fuel

Change

Inferior check valve (foreign matter)

Replace

Inferior manifold o-ring

Replace

Poor tightening of carburetor

Tighten

Malfunction of carburetor control (metering) lever

Replace

Poor installation of carburetor control lever

Correct

Damaged main diaphragm

Replace

Adherence of inlet needle valve

Replace

Foreign matter sticking of needle valve

Clean

Idling needle pin maladjustment

Adjust

Idling adjust screw maladjustment

Adjust

Foul fuel tank filter

Clean

Clogged fuel line

Clean

Air leakage in fuel line

Repair

Inferior check valve (foreign matter)

Replace

Too high carburetor control (metering) lever

Adjust

Malfunction of carburetor control (metering) lever

Replace

Deformation of carburetor control (matering) lever spring

Replace

Poor installation of carburetor control lever spring

Correct

Inlet needle valve wear

Replace

Foreign matter sucking of inlet needle

Clean

Idle needle pin maladjustment

Adjust

Clogged fuel tank cap air vent

Clean

Foul fuel tank filter

Clean

Clogged fuel line

Clean

Air leakage in fuel line

Repair

Pulse leakage from fuel pump

Repair

Clogged pulse passage

Clean

Poor tightening of pump cover screw

Tighten

Inferior of pump diaphragm

Replace

Inferior of check valve

Repair

Inferior of manifold o-ring

Replace

Poor tightening of carburetor

Tighten

Damaged carburetor control (metering) lever

Replace

Too low carburetor control (metering) lever

Adjust

Malfunction of carburetor control (metering) lever

Replace

Poor installation of carburetor control (metering) lever

Correct

Damaged carburetor control (metering) lever button

Replace

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For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983

SUPPLEMENT 4-9
Rotary Valve, Diaphragm Type Carburetor Troubleshooting
Symptom

Cause

Remedy

Poor tightening of diaphragm cover

Tighten

Damaged diaphragm

Replace

Adherence of inlet needle valve

Replace

Idle needle pin maladjustment

Adjust

Inferior pump diaphragm

Replace

Too high carburetor control (metering) lever

Adjust

Malfunction of carburetor control (metering) lever

Replace

Inlet needle valve wear

Replace

Foreign matter sticking of inlet needle

Clean

Engine does not accelrate

Idle needle pin maladjustment

Adjust

quick

Clogged air cleaner element

Clean

Malfunction at high speed

Clogged fuel tank cap air vent

Clean

Foul fuel tank filter

Clean

Clogged fuel line

Clean

Air leakage in fuel line

Repair

Improper fuel

Change

Pulse leakage from pulse passage

Repair

Clogged pulse passage

Clean

Poor tightening of pump cover screw

Tighten

Inferior of pump diaphragm

Replace

Inferior of check valve

Replace

Clogged air cleaner element

Clean

Inferior of manifold o-ring

Replace

Poor tightening of carburetor screw

Tighten

Damaged carburetor control (metering) lever

Replace

Malfunction of carburetor control (metering) lever

Replace

Deformation of carburetor control (metering) lever spring

Replace

Poor installation of control lever spring

Correct

Damaged main diaphragm button

Replace

Inferior of main diaphragm gasket

Replace

Poor tightening of main diaphragm cover

Tighten

Damaged main diaphragm

Replace

Inlet needle valve wear

Replace

Foreign matter sticking of inlet needle

Clean

Engine stops when decelrating

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