FUEL TANK VENTING Fuel tanks must be vented to prevent vacuum forming and stopping flow of fuel.

Tank caps have a plainvent hole. A closed vent will create a vacuum in the tank a s fuel is used the engine will run a few minutes and stop. In a few minutes the vacuum will decrease and the engine can be started again, but it will stop again in a few minutes. The vent hole can become clogged with dirt., inspect and clean ,as required.

D - 4 0 0 SERIES FUEL SYSTEM INSPECTION

SHUT-OFF VALVE

be checked easily by removing the fuel hose,

The screen assembly or the shut-of valve can become clogged. This can opening the valve and observing for fuel flow through the valve. Replace the valve and screen assembly if gummed up, rusted, or if packing is damaged. NOTE Shut-off valve should be open and packing nut loose before screwing assembly into Secure assembly to t n , then close valve ak and tighten packing nut. Wing should turn easily, but snugly.

t n. ak

AIR FILTER If enginei flooded, fuelcan drain back into filter. As s filter becomes saturated, incoming air picks up more fuel, causing greater flooding. A puckered filter will allow air and dirt to bypass filter. Make certain that filter covers cup area. If oiled, properly,filter is very efficient. First wash out with hot, soapy water.Wring out and dry completely, then apply 10 to 15 drops of oil. Squeeze several times to distribute oil. If engine smokes for no apparent reason,check filter for flooding and a rich running condition.

Later D-400 Seriesmodels have a plastic air cleaner. To remove grasp the cover lip and pull back o r fold down as required.

FUEL L I N E Inspect the fuel line, If cracked, spongy, or otherwise not fit for good safe use, replace. DONT TWIST FUEL LINE INSERT ON CONNECTIONSWITHFINGERS, NOT PLIERS.

NOTE the Reinstall filter in same which it was removed.

position

SAFETY WARNING DO NOT SUBSTITUTE WITH INFERIOR FUEL HOSE WHICH MAY CAUSE LEAKAGE FROM PREMATURE DETERIORATION. LEAKAGE OF FUEL MAY CAUSE AN EXPLOSIONAND/OR FIRE.
SERVICE BULLETIN REFERENCES

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4-5

REVISED 1977

D - 4 0 0 SERIES F U E L S Y S T E M INSPECTION
NOTE Some later model D-400 engines a r e equipped with the D-600 Series fuel system. A thorough visual inspection will determinethefuelsystem used on the engine.
FLOAT VALVE

The float valve consists of a needle and seat assembly, activated with a float in the float bowl. Theneedle is steel with rubbertip seat brass, materials which will and the not readily adhere together. needle The rests on the float arm, (held in place by a spring clip on later models). Operation is automatic. When the float bowl is empty,thefloat rests on the bottom of the bowl. As fuel enters bowl of carburetor, the float rises, moving needle into seat and shutting off fuel. As the engine usesfuel, the float drops slightly, allowing more fuel toenter bowl, maintaining a constantfuel level in bowl. The needle and seat must be replaced as an assembly. 'They a r e matchedform to a perfect seal.

Some of the problems you may encounter with the float valve are a s follows: Cause
GUM IN FUEL

Effect Stops up openings Needle may stick shut Fuel supply can't be shut off from float bowl Set too high carburetor floods Set too low carburetor starves

Remedy *Clean out carb. with solvent Replace Clip Replace Needle and Seat as an Assembly Set correctly Set correctly Replace Pin Replace Float *Replace Float

SPRING WIRE CLIP COMES OFF

NEEDLE AND SEAT NOT

MATCHED FLOAT ARM NOT SET RIGHT

PIVOT PIN CORRODED OR BENT FLOAT STRIKING NOZZLE VARNISH OFF FLOAT

Float sticks Float sticks Float soaks up fuel, changing floating characteristics

is *Never allow a strong solvent to come in contact with the float. The cork float coated with an epoxy sealer. If the solventremovesthe epoxy, thefloat will absorb gasoline and its floating characteristics will change.
4-6

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REVISED 1977

SERVICE BULLETIN REFERENCES

D - 4 0 0 SERIES CARBURETOR

ADJUSTMENTS

N E E D L EA D J U S T M E N T

To adjust needle, turn adjusting knob clockwise needle until seats lightly; DO NOT FORCE NEEDLE DOWN TOO TIGHT, SINCE YOU MAY DAMAGE NEEDLE OR SEAT I N NOZZLE AND MAKE FURTHER ADJUSTMENT DIFFICULT.

Then open needle two turns. Start engine. If engine begins die, to open carburetor adjusting knob by turning counterclockwise. If engine runs roughly, close knob by turning clockwise until engine smooths out. Let engine run for about 5 minutes to warm up. Closeadjusting knobslowlyuntilengine beginsto die, then open adjusting knob 1/4 to 1/2 turn.

Carburetors on earlier "D" 400 modelengines also contain a slow speed adjustment. The correct setting for this adjustment is 1 turn open. If an engine runs ROUGH o r "HUNTS" at the "low" speed setting it can be leveled out by opening, o r closing this adjustment.
SERVICE BULLETIN REFERENCES

engines the low On later "D" 400 model speedneedleadjustingvalve hasbeenreplaced with a fixed jet. This jet is pressed into the low speed passage and the passage opening is sealed with a lead shot.

. . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7

D - 4 0 0 SERIES .CARBURETOR SERVICING

FLOAT SETTING

Remove float bowl and gasket.Invert carburetor. With float arm resting on float valve needle, the top of float should be 15/32 inchaboveedge of carburetor body. To adjust; bend metal a r m with needle nose pliers. NOTE

DO NOT attempt to bend by applying pressure to cork float.

Carburetorservicingconsists of inspection,cleaning, adjustment, and replacement of faulty parts. Toremovecarburetorfromengine,carburetor and reedplatemustberemoved as an assembly,. and reed plate removed from carburetor. Carburetor service assemblies include 2 thread forming screws. The reed plate mounting flange on the carburetor is drilled but not tapped. These screws form a very tight fit eliminating the possibility of screws vibrating loose during engine operation.

UNTAPPED MOUNTING HOLES

THREAD FORMING SCREWS

The metal carburetor body can be cleanedwith a good solvent and blown dry with air, EXCEPT THE CORK FLOAT. A solvent will remove the varnish from the float. Inoperative floats should be replaced. DO NOT DRYCARBURETOR PARTS WITH A CLOTH, because lint may stick to the parts and cause trouble in

the reassembled carburetor.

for Inspect valve needles grooves or other defects. If grooved or otherwise defective, replace. Use a magnifying glass in the inspection. Tiny scratches or worn surfaces affect the operation.

4-8

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SERVICE BULLETIN REFERENCES

D-400 SERIES CARBURETOR SERVICING

The reed plate can be cleaned with solvent with the rest of the carburetor. Be careful in handling reeds, so as not to distort them. The reeds mustlieflatagainst the reedplate to form a perfectseal. Bent or otherwise damaged reeds cannot be repaired. Check the reed plate for warpage. DO NOT USE COMPRESSED AIR ON REEDS, The rough edge of the reed should be away from the plate.
MACHINED SURFACE

Maximum clearance allowed between reed tip and reed plate is .015. If clearance exceeds this, reeds must be replaced.

SERVICE BULLETIN REFERENCES

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4-9

D-400 SERIES CARBURETOR

SERVICING

FUEL NOZZLE FILTER

Thenozzle filter will provide a secondary filtering device to minimize the possibility of "fuzz" or other minute particles getting into the carburetor area, which causes engine stalling. Prior to installing nozzle filter clean carburetor, high speednozzle,fuel tank, fuel shut-off valve and filter assembly. High speednozzlemustberemovedtoclean it properly. Install filter on the nozzle firmly.
DO NOT slide neoprene over ring fuel passage hole.

Hold float up and lift bowl carefully in place. (For easier installation, take carburetor off and turn upside down.) r

FILTER PART NO.

607637

L-

FUEL FILTER IN PLACE ON NOZZLE

D - 4 0 0 SERIES ENGINE C A R B U R E T O R S E R V I C I N G H I N T S
LOW SPEED NEEDLE ASSEMBLY

LEAD SHOT

FUEL INTO
CARB VENTURI

4-10

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SERVICE BULLETIN REFERENCES

D - 4 0 0 ENGINE CARBURETOR SERVICING HINTS (CONT)

D-400 SERIES CARBURETOR THROTTLE S S H A F T I SPLIT FORTHROTTLEDISC MOUNTING. FLATTED SIDE

ALWAYS PLACE CORRECT TENSION ON THROTTLE SHAFT SPRING WHEN INSTALLING. CARBURETOR BODY

7/3 2

THROTTLE SHAFT

THREADS

SLOT
C

T H ES H A F TS I Z E I LARGER S THAN ENGINE THROTTLE SHAFTS.

HOOK END IN CARBURETOR BODY AND 1/2 ADD TENSION TURNING BY SPRING 3/4 TURN AND HOOK ON THROTTLE SHAFT ARM.

ENGINE S U R G I N G DUE TO C A R B U R E T I O N
Surging explanation: High to LowR.P.M. constantly,
2. Throttle shaft may wear causing shaft and/or throttle disc to bind. Replace shaft and disc.

1. A burr on the throttle shaft arm which holds governor rod in place can cause a drag. can This contribute to surging. Repair - clean off burr, check governor rod for wear.

3. Improper adjustment.

SERVICE BULLETIN

REFERENCES

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4-11

FUEL INFORMATION

NOTE Your LAWN-BOY uses a two cycle engine. This means the oil and gasoline must be mixed together. Failure to use theproper fuel mixture will result in serious damage to the engine. GASOLINE - Use automotive regular grade with a minimum of 89 pump octane, No-Lead or lead free gasoline of 86 pump octane is satisfactory if owner wishes to use it. DO NOT USE GASOHOL OR OTHER GASOLINES THAT CONTAIN ETHANOL OR METHANOL. LUBRICATION (OIL)Use LAWN-BOY2 cycle ol i availablefrom your LAWN-BOYdealer. If not readiy available, use a good grade of two cycleol from l i a reputable ol company. DO NOT USE AUTOMOi TIVE OILS. FUEL MIXTURE

SAFETY WARNING GASOLINE IS EXTREMELYFLAMMABLE AND HIGHLY EXPLOSIVE UNDER CERTAIN CONDITIONS. ALWAYS STOP ENGINE, AND DO NOT SMOKE OR ALLOW OPEN FLAMES OR SPARK WHEN REFUELING.

Use clean container. Mix thoroughly. DO NOT mix fuel directly in mower fuel tank.
CORRECT FUEL MIXTURE (CURRENT MODELS) U e LAWN-BOY SPECIAL 2-cycle oil. M i x one s full can with 2 gallons (U.S.) gasoline. of NOTE

Follow instructions on can.

If you use OTHER 2-CYCLE oil, mix 8 ounces (U.S.) with 1 gallon (U.S.) of gasoline.

(OLDER MODELS)
M i x one full can of Lawn-Boy 2-cycle oil with 1gal-

lon (U.S.) regular gasoline. Refer to owners manual for instructions.

4-12

........................................
REVISED 1983

SERVICE BULLETIN

REFERENCES

D - 6 0 0 SERIES FUEL SYSTEM

PRINCIPLES OF CARBURETION NOTE Some later model D-400 engines are equipped with the D-600 series fuel system. A thorough visual inspection will determine the fuelsystem used on the engine. SAFETY WARNING
DO NOT SUBSTITUTE WITH INFERIOR FUEL HOSE WHICH MAY

FUEL TANK VENTING Fuel tanks must be vented to prevent vacuum forming and stopping flow of fuel. Tank caps will have a vent hole. A closedvent will create a vacuum in the tank as fuel is used andeventuallycausetheengineto stop. In a few minutes the vacuum will decrease and the engine can be started again, a shortperiod of but it will stopagainin time. The hole become vent can clogged with dirt. Checkventhole before each operation and clean if necessary.

CAUSE LEAKAGE FROM PREMATURE DETERIORATION. LEAKAGE OF FUEL MAY CAUSE AN EXPLOSIONAND/OR FIRE. Thecarburetorused on Solid State (C.D.) ignitionengines is automatic. No fuel adjustments are necessary,toregulatefuel the intake.single, A metered allows jet correct amount of fuel to mix with the incoming air which is regulated by a single adjustingneedle that is explained on page 4-15 of this section. Adjustment must be changed when a significant changein altitude is encountered.

FUEL TANK FILTER

FUEL T A N K

GASKET

DJUSTMENT

T
DRAIN VALVE CLIP

FUEL CAP

SHUT-OFF VALVE The fuel tank screen assembly or the shutoff valvecanbecome clogged. Thiscan be checked easily by removingthefuelhose, opening the valve and observing fuel for Replace the fuel flow through the valve. shut-off assembly if damaged.

FUEL C A P

GASKET

Shut-off valve is secured to fuel tank with a spring exercise clip; care when re-installing to fuel tank.
SERVICE BULLETIN REFERENCES

............ ...........................
REVISED 1977

4-13

D - 6 0 0 SERIES FUEL SYSTEM

AIR FILTER AIR VENT PASSAGE

-ELEMENT

A I R FILTER ASSEMBLY
FILTER AIR

I engine is flooded, fuel can drain back into f filter. A s filter becomes saturated, incoming air picks up more causing fuel, greater flooding. A puckered filter will allow air and dirt tobypass filter. Make certain that filter covers cup area. If oiled NOTE properly, filter is very efficient. First wash out with fuel, then apply 10 to 15 drops of oil. Squeeze several timesdistribute to Reinstall filter in same the position oil. If engine smokes for no apparent which it was removed prevent to reason, filter may be saturated with fuel imbedded particles in intake side mix o r may cleaning. need entering from carburetor. Install air filter case correctly. Hinge on To remove grasp cover, the loosen snap and bottom. If installed upside down the fold cover down. air vent passage will be blocked.

Examine the primer system. Instead of into the float bowl chamber which forces lifting fuel up in the carburetor throat as fuel in into the carburetor venturi. the case with some D-400 series engine, the pneumatic primer forces compressed air
4-14

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SERVICE BULLETIN REFERENCES

D-600 SERIES FUEL SYSTEM

1-1/2 TURNS SETTING

AIR ADJUSTMENT

utes to make sure adjustment lean.

6. Place

is not too

The carburetor is completely automatic. There are no adjustmentsto be made to regulate the amount of fuel entering the carburetor venturi. There is an atmospheric pressure adjustment that would have to be made if the engine is operating very in high o r very low altitudes.
All D-600 series andmodular carburetors require a finaladjustment of the altitude needle prior to puttingmower the into service.

speed control in lever HIGH SPEED position running (3100-3300 R.P.M.) Observe engine operation. If not running smoothly, turn altitude needle counterclockwise approximately 1/4 turn at a time to obtain proper engine operation.

To adjust, proceed as follows:

1 Pre-set altitude needle 1-1/2 turns from .

seat.
2. Start engineandallow

7. After carburetor adjustment is completed, shut off engine. IMMEDIATELY attempt to restart engine. It should start within 2 pulls on starter handle. Check starting engine at both HIGH and LOW speed settings. If difficult to restart, turn altitude needle 1/8 to 1/4 turn counterclockwisetorichenfuelmixture and obtain easy restarting.

to run for

3 to 5

minutes to warm up. 3. Place speed control lever in LOW SPEED running position (2400-2600 R.P.M.)
4. Turnaltitudeneedleclockwiseuntilen-

DO NOT PRIME A HOT ENGINE.

NOTE The governor will control the amount of fuel entering the engine. The purpose of the atmospheric pressureadjusting needle is to mix the right amount of fuel with the correct amount of incoming air.

gine starts to "hunt," ''surge" or slow down.

5. Slowly turn altitude needle counterclockwise until engine is running smoothly. Allow engine to run for one or two min-

SERVICE BULLETIN

REFERENCES

........................................

4-15

D - 6 0 0 SERIES FUEL SYSTEM

AIR ADJUSTMENT
( Continued )

NOTE In the closed position no air is entering the carburetor ventpassage. Therefore, the float bowl pressure has been eliminated and the fuel supply tothe carburetorventuri is cut off.
FLOAT AND VALVE

CLOSED SETTING

Examine float appearance. Should be glossy because of epoxy sealer. If dull in appearance, o r portions of epoxy has chipped away replace.

NOTE

Do not cleanfloat with any type of solvent or carburetor cleaner. Clean with standard fuel mix.

The float valve consists of a needle and seat assembly,activated by a floatinthe carburetor bowl. The steel needle is rubber tipped and theseat brass. This combinationeliminatespossiblesticking and provides a perfect seal. Theneedle rests on float arm, held inplace by a spring clip.

Operation is automatic. When float bowl is empty, float rests on bottom of bowl, As fuel enters bowl of carburetor, float rises, moving needlevalveinto seat and shutting off fuel. As engine uses float fuel, drops slightly, allowing more fuel to enter bowl, maintaining a constantfuellevelin bowl.
Needle and seat must be replaced as an assembly. They are matchedtoform a perfect seal.

NEEDLEVALVE

FLOAT

DUMP VALVE ASSEMBLY

GASKET

NOTE:
4-16

Check dump valve and gasket for distortion o r damage.

SERVICE BULLETIN REFERENCES

........................................

D - 6 0 0 SERIES FUEL SYSTEM

Some of the problems you may encounter with the float valve a r e a s follows: Cause
GUM IN FUEL SPRING WIRE C LIP COMES OFF

Effect Stops up openings Needle may stick shut *Clean out carburetor with solvent Replace clip

NEEDLE AND SEAT NOT MATCHED FLOAT ARM NOT SET CORRECTLY

Fuel supply can't be shut Replace needle and seat as an off from float bowl assembly Set too high carburetor Set correctly floods Set too low carburetor Set correctly starves PIVOT PIN CORRODED OR Float sticks Replace pin BENT Replace float FLOAT STRIKING NOZZLE Float sticks Float soaks up fuel, chang- *Replace float VARNISH OFF FLOAT ing floating characteristics

BEND ARM HERE TO ADJUST

2

and screw assembly part 681008. If replacement of shaft or disc is necessary, use this assembly number.

Disc is secured to shaft with screw as illustrated.

FLOATADJUSTMENT
FLOAT SETTING

Removefloat bowl andgasket.Invert carburetor. With float arm resting on float valve needle, top the of float should be 15/32 inch above edge of carburetor body as shown. To adjust; bend float arm with long nose pliers.

DO NOT bend by applying pressure to float. cork Bend arm only by grasping with pliers.
THROTTLE SHAFT AND VALVE (DISC) SERVICING

Early 1972 productionmodelsusedplastic throttle shaft and snap-in disc. Later 1972 production models include bronze shaft, disc
SERVICE BULLETIN REFERENCES

1 Remove reed plate assembly. .

4-17

........................................

D - 6 0 0 SERIES FUEL SYSTEM

2. Usingneedlenose

pliersgraspthrottle disc and remove disc from throttle shaft. Inspect disc for wear or burrs. Replace if necessary with shaft, disc and screw assembly part no. 681008.

3. Remove '"E" ring and slide throttle shaft from carburetor body. Inspect plastic throttle shaft for wear and replace if required with shaft, disc and screw assembly part no. 681008.
4. Reassemble in reverse making order suresmall holeinthrottle disc is installed facing reed plate assembly.

NOTE Always correct place tension on throttle shaft spring when installing. Hook end in carburetor body and add tension by turningspring 3/4 turn and hook on throttle shaft leaf as illustrated on page 4- 11.
REED PLATE SERVICING

1. Reed plate assembly may be cleaned with samesolventusedtocleancarburetor. Exercisecarein handling reeds, so as not to distort them. Bent ordistorted reeds must be replaced.
2. Check forexcessiveclearance between reedtip and reedplate as illustrated. Maximum allowed clearance .015 inch.
MACHINED SURFACE

3. Reeds must be installed with rough edge away from plate as shown.
NOTE

DO NOTUSE COMPRESSED AIR TO

CLEAN REED VALVES.
ROUGH EDGE

4-18

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SERVICE BULLETIN

REFERENCES

MODULAR CARBURETOR
M O D U L A R CARBURETOR C O M P O N E N T S

CARBURETOR BODY
"0" RING

The new modular carburetor was introduced in the 1975 D-600 s e r i e s engines and later production D-400 s e r i e s engines. This new carburetor is constructed of a special injection molded plastic material. The body and air filter chamber is a one-piece plastic assembly which "plugs" into the reed plate and is secured by a singlescrew. An Oringinstalled between thecarburetor and reed insures plate positive sealing. The float and fuel valve is also a one-piece assembly. assembly This rests on a spring located the in plastic float chamber. The spring provides vertical tension against the float forcing the fuel valve into the fuel inlet seat when thefloatchamber is full of fuel. As fuel enters a single metered jet it is mixed with incoming air to form the correct combustible mixture. amount The of fuel flow through the metering jet is regulated by the altitude needle. Adjustment procedure is same as earlier D-600 series carburetors. Refer to page 4-15 for adjustment procedure.

FLOAT AND V E ASSEMBLY

PLATE ASSEMBLY FLOAT CHAMBER

The governor will control the amount of fuel entering the engine. The purpose of the atmospheric pressure adjusting needle is to mix the right amount of fuel with the correct amount of incoming air.

SERVICE BULLETIN REFERENCES

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.

4-19

MODULAR CARBURETOR
O-R I N G

surface of the carburetor barrel and the inside diameter of the reed plate opening. The correct procedure to install the carburetor is to lubricate the O-ring in groove of the reed plate and "plug" in the carburetor.
An O-ring seals between theouter

When installingorremovingcarburetor from engine, the governor rod must be removedfromthethrottle arm.
CLEANING CARBURETOR

damage, for altitude needle Check spring DO NOT BEND SPRING. for damage The carburetorassembly is injection molded Check gasket forcracks or wear. Always plastic. DO NOT clean using a standard use new gasket during reassembly. carburetorcleaner.DisassemblecarbureNOTE tor components,washand cleanusing a good grease solvent, dry and clean parts with compressed air DO NOT dry using a If any part appears worn o r damaged, ensure float cloth, lint may block passages impeding replace it. To proper proper action carburetor operation. the float must be correctly installed in float chamber(not binding). After cleaning, inspect all parts. Check After assemblingchamber float to float fuel and valves for cracks or damage. carburetor body shake in a vertical Check throttle valve spring shaft, and for motion and listenfloat for movesmooth operation. Check float chamber for ment. If no sound (movement) is cracksor damage. Check dump valve and heard remove float chamber and regasket distortion for or damage. Check install correctly.

ALTITUDE CARBURETOR BODY NEEDLE

I

DUMP VALVE

FLOAT

CHAMBER

4-20

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SERVICE BULLETIN

REFERENCES

MODULAR
FLOATSPRING

The spring float operation.

is very critical

in its

It providesverticalpressuretothefloat and fuel valve forcing the fuel valve into the fuel inlet to stop the flow of fuel when the bowl hasfilled.Each end of the spring is located in a recessedarea. The walls of these recesses provide guidance for vertical movement of the float and fuel valve. Without these walled recesses the float and fuel valve would move laterallypreventingthe fuel valve from entering the fuel inlet seat squarely. Mowing at an angle such as a terrace could result in a carburetor flooding without these recesses.

DO NOT ATTEMPT TO CHANGE THIS SPRING DIMENSIONALLY. A specific free length dimension of 5/8" (.625 .030) is required to complete its function.
AIR FILTERASSEMBLY

FILTER

If engine is flooded, fuel can drain back into filter. As filter becomes saturated, incoming air picks up more fuel, causing filter will greater flooding. A puckered allow air and dirt tobypassfilter. Make certain that filter covers cup area. If oiled properly, filter is very efficient. First wash out with fuel, then apply 10 to 15 drops of oil. Squeeze several times todistribute oil. If engine "smokes" for no apparent with fuel reason,filter may besaturated mix or may need cleaning.

~,

PRIMER ACTIVATED

To remove the graspdetachable cover, loosen snap and fold cover down.

Reinstall filter in the same position which it was removedprevent to imbedded particles in intake side from entering carburetor.
PRIMER

Examinetheprimersystem. A pneumatic primerforcescompressedair into float the bowl chamber which forces fuel the into carburetor venturi.
SERVICE BULLETIN REFERENCES

............ ...........................
REVISED 1977

4-21

MODULAR CARBURETOR
FUEL A N D P R I M E R HOSE R O U T I N G

DO NOT SUBSTITUTE WITH INFERIOR FUEL HOSE WHICH MAY CAUSE LEAKAGE FROM PREMATURE DETERIORATION. LEAKAGE OF FUEL MAY CAUSE AN EXPLOSIONAND/OR FIRE.

PLASTIC CARBURETOR BODY Proper hose routingrequirestheprimer hose to be twisted counterclockwise approximately 1/2 turn around the fuel line. This will preventthe starter pulley fromdamaging the hoses. Exercise care when installing hoses.

Do not pull hoses taut in either direction. Leave sufficient slack in hoses to prevent contact with starter pulley.

COUNT AROUN

METALCARBURETORBODY Properhoseroutingrequiresthehosesto be parallel with each other as shown. If twisted, it is possible for hoses to be damaged by starter pulley. Exercise care when installing hoses.

4-22

........................................
REVISED 1977

SERVICE BULLETIN REFERENCES

D - 6 0 0 SERIES FUEL SYSTEM TROUBLE SHOOTING

FUEL SYSTEMTROUBLESHOOTING

1. Check for fuel in tank.

A. Fuel shut off (Tank) valve should be open.

B. Examine vent hole in gas cap. Make sure it is not restricted.

2. Remove air filter element. A. Watch nozzle in barrel of carburetor and push primer bulb down rapidly.

B. Fuel should spurt from top of nozzle.

3. If spurting of fuel is not visible.

A. Remove fuel line from carburetor to determine if fuel is flowing from tank thru tank filter, valve and hose.

B. If not, remove hose from tank valve. Turn valve on to determine if fuel is flowing from tank. I f so, restriction is in fuel hose. Wash out in solvent and blow with compressed air.
4. Check function of primer bulb and hose.
A. Place finger over lower end of primer hose and press primer bulb. Resistance should be noted in bulb depression. Remove finger, there should be no resistance present when bulb is depressed.

B. Depress primer bulb and place finger over end of hose. The bulb should remain collapsed. I not, f replace primer bulb and hose assembly.
5. If fuel is spurting from nozzle,

A. Check float valve and seat assembly.

when being primed, close fuel valve and remove carburetor and reed plate assembly. Remove float chamber.

B. Check float level adjustment.* C. Check to make sure movement of float and float arm is free.*
D. Check the throttle valve and shaft for freedom of

movement.
E. Remove metering nozzle and check for re-

striction. *

F. Blow out altitude air vent passage.

G. Check setting and condition of reed valves. *NOT APPLICABLE TO MODULAR CARBURETOR

SERVICE BULLETIN REFERENCES

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REVISED 1977

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4-23

MODULAR CARBURETOR UTILITY MODELS

MODULAR CARBURETOR COMPONENTS AIR FILTER ASSEMBLY

The new modular carburetor was introduced in the 1979 D-410 seriesenginesonallutilitymodels. This new carburetor is constructed of a special injection molded plastic material. The body and air filter chamber is a one-piece plastic assembly which plugs into the reedplateandissecuredbya single screw. An O-ring installed between the carburetor and reed plate insures positive sealing. The modular carburetor has been redesigned featuring a new float chamber, gasket, float and carburetor body. A hinged type float of special cork material is sealed with an epoxy. During inspection, if. the float appears dull or dark in appearance it should be replaced. The float in this new modular carburetor positioned is differentlyprevious than modular carburetors with the float upsidedown, and a float level adjustment requirement of 11/16 inchesfromcarburetorbody to top of float. As fuelentersasinglemetered jet it ismixedwith incoming air to form the correct combustible mixture. amount The of fuel through flow the metering jet isregulatedby the altitude needle. NOTE The governor will control the amount of fuelentering the engine.Thepurposeof the atmospheric pressure adjusting needle is to mix the right amount of fuel with the correct amount of incoming air. NOTE
is also a This modular new carburetor Service replacement component all prefor A vious D-Series modular carburetors. Quick inspection show visual will you which modular carburetor is the engine. on

If engine is flooded,fuelcandrainback into filter. As filter becomes saturated, incoming air picks up morefuel,causinggreaterflooding. A puckered filter will allow air and dirt to bypass filter. Make certain that filter covers cup area. oiled properly, If filter isvery efficient. First wash out withfuel, then apply 10 to 15 drops of oil. Squeeze several i. times to distribute o l If engine smokes for no apparent reason, filter may be saturated with fuel mix or may need cleaning. To remove grasp the detachable cover, loosen snap and fold cover down.

CARBURETOR

BODY

FLOAT CHAMBER

NOTE Reinstall filter in the same position from which it was removed to prevent imbedded particles in intake side from entering carburetor.

CARBURETOR REMOVAL 1. The modular carburetor is attached to the reed plate assembly by a single screw.
4-24

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SERVICE BULLETIN REFERENCES

MODULAR CARBURETOR

- UTILITY MODELS

During reassembly apply Lawn-Boy nut and screw lock part no. 682301 to threads of mounting screw.
2. Pull carburetor reed assembly. from plate Do not bend or damage the governor rod and/or throttle arm of the carburetor.

CLEANING CARBURETOR

The carburetor assembly is injection molded plastic. DO NOT clean using standard carburetor cleaner a Disassemble carburetor components, and wash cleanusing a goodgreasesolvent,dryandclean parts with compressed air - DONOT dry using a cloth, lint mayblockpassagesimpedingproper carburetor operation. Aftercleaning,inspectallparts.Checkfloatand fuel valves forcracks or damage.Check throttle shaft, valve spring and for smooth operation. Check float chamber for cracks or damage. Check altitude needle and O-ring for damage.Checkair vent passage which allows air to flow intothe float chamber. If this passage should become restrictedwith dirt and/ordebris the enginewill not run correctly or stop running and flooding of carburetor willoccur.Checkgasketforcracksor wear.Alwaysusenewgasketduringreassembly.

3. Check O-ring in reed plate assemblyfor damage. We recommend replacing O-ring every mowing season during and all tune-up operations.
O-RING
An O-ringsealsbetween

the outer surfaceof the carburetorbarreland the insidediameterof the reed plate opening. The correct procedure install to the carburetor is to lubricate the O-ring in groove of the reedplateandplugin the carburetor.
CARBURETOR

VENT

AIR PASSAGE

NOTE If any part appears worn or damaged, replace it. To ensure proper float action the float mustbecorrectlyinstalledinfloat chamber (not binding). Use needlenose pliers to secure hinge on float arm to pin.
SERVICE BULLETIN REFERENCES

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MODULAR CARBURETOR
FLOAT AND VALVE ASSEMBLY

- UTILITY MODELS

The float valveconsistsofaneedleandseat assembly, activated by a float in the carburetor bowl.Thesteelneedle is rubbertippedand the seat brass. combination This eliminates possible stickingandprovides a perfect seal. Theneedle rests on float arm, held in place by a spring clip. Operation is automatic. When float bowl is empty, float rests on bottom of bowl. As fuel enters bowl of carburetor, float rises, moving needle valve into As float seat and shutting off fuel. engine uses fuel, dropsslightly,allowingmorefuel to enter bowl, maintaining a constant fuel level in bowl.
as Needle, seat and spring clip must be replaced an assembly. They are matchedto form a perfect seal.

Remove float bowl and examine float appearance. Float should be glossy because of epoxy sealer. If dull appearance, in or portions of epoxy have chipped away - replace float. NOTE Do not clean float with any type of solvent or carburetor cleaner. Replaceit. Some of the problems you may encounter withthe float valve are as follows: Effect VARNISH SPRING WIRE CLIP COMES OFF NEEDLE AND SEAT NOT MATCHED FLOAT ARM NOT SET CORRECTLY Stops up openings Needle may stickshut Fuel supply cant be shut
off from floatbowl

Remedy Clean out carburetor with solvent Replace clip Replace needle and seatas an assembly Set correctly Set correctly Replace pin Replace float Replace float Crimp float hinge clip on pivot pin for tighter fit
SERVICE BULLETIN REFERENCES

Set too high - carburetor floods - Engine runs rich Set too low - carburetor starves - Engine runs lean

PIVOT PIN CORRODED OR BENT FLOAT STRIKING NOZZLE VARNISH OFF FLOAT LOOSE FLOAT HINGE CLIP ON PIVOT PIN
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Float sticks Float sticks Float soaks up fuel, changing floating characteristics Engine 4 cycles excessively when bumped or jarred

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MODULAR CARBURETOR = UTILITY MODELS

FLOAT ADJUSTMENT

Float Setting Remove float bowl and gasket. Invert carburetor. With float arm restingon float valve needle, the top of float should be 11/16 inch above edge of carburetor body as shown. Obtain measurements at two points at right angles to each other. If adjustment is required; using needle nose pliers bend float arm as shown. DO NOT bend float arm by applying pressure to float, this will damage rubber tip on inlet needle.
MEASURE AT RIGHT ANGLES

FLOAT VALVE AND SEAT ASSEMBLY

NOTE The float valve and seat must be replaced as an assembly. They are matched to form a perfect seal.
1. Remove hinge pin and remove

float and valve. Remove spring clip securing valveto float am r.

Check hinge on float arm to be sure it is secured to pin.Useneedlenosepliersandtightenhinge. The hinge should be clamped tight enough so that the pin will swivel in the carburetor instead of the arm turning on the pin. NOTE Tightening hinge to pivot pin will prevent inlet needle from not seating correctly whenmowercrossesuneventerrain.This condition is called fluttering. Check pin clip on float arm by rotating carburetor sideways. If clipfallsoff float arm -- replace it.
SERVICE BULLETIN REFERENCES

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MODULAR CARBURETOR

- UTILITY MODELS
The pre-setting position is ONE TURN OFF THE SEAT. Use caution when installing this needle as damage occur may to the carburetor body orthe needle ifit is tightened excessively,

2. Use a wide bit screwdriver to remove or install seatfromcarburetorbody. When reinstalling the seat, tighten securely. Exercise care when tightening seat to prevent damaging the seat.

ALTITUDE NEEDLE

The altitude needle has a rubber O-ring around it to seal the threadsandpreventairfromleaking through. It also serves as a locking feature to prevent the altitude needle from vibrating out of carburetor body.

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SERVICE BULLETIN REFERENCES