6 Carburettor Reassembly
Once all of the components have been cleaned and checked for damage and wear, the carburettor can be reassembled.
If the choke assembly was dismantled then begin by reassembling it. Slide on the metal sleeve as illustrated below.
Assemble the fast-idle cam, spring, and bushing.
Put the fast-idle cam assembly on the metal sleeve and insert the choke shaft. This operation is a little tricky as the little plastic crank must be fitted to the choke shaft at the same time.
Attach the choke carrier with the three slotted cheese-head screws and ensure that the spring is fitted correctly.
With both throttle levers in their rest position (idle position), measure clearance Z on the secondary throttle plastic lever. It should be between 0.1-0.5mm. If it is out of specification it might indicate that the plastic lever is worn where it rubs against the primary throttle metal lever. Wear in this area can be filled with a suitable filler. After making any repair on the plastic lever, remember to check clearance Z again. In order to correct the clearance, bend back the metal forks.
Pull the plastic secondary throttle lever clockwise (releasing the lever should cause it to return by action of its return spring). Now measure clearance Y. It should be between 0.15-0.85mm. Correct clearance if necessary.
Make a sandwich of gaskets, in the order gasket-insulator-gasket, and place it between the main body and the throttle body. Fix the two bodies together using the single screw underneath the throttle body.
Open the primary throttle and rotate the choke lever until the fast-idle screw butts against the sixth step of the fast-idle cam. Measure the clearance between the primary throttle lever and its idle stop screw. This clearance is called the 'fast idle gap'. Note: Do not adjust the idle stop screw to modify this clearance. If the clearance is not within specification, adjust the fast-idle screw.
