Insert the cam back into place and ensure that it is moving correctly, that it does so with relative ease. Turn the cam clockwise as far as it will go and then begin to reinsert the throttle cable – thread the cable into the appropriate grooves to hold it in place and slot the gold ball at the end of the cable into the cam (having the throttle in the off position makes this easiest).
Next re-install the ignition wires by first turning the throttle to the middle position then place the cover and plug over the wires and insert the red wire through the hole in the body of the carburetor where it is supposed to go, push the cover flush against the carburetor body. The second ignition wire will be inserted at 90 degrees to the first, you will notice there are holes in the cover for this wire to be threaded through.
Place the poppet valve through the designed hole from the bottom of the carburetor body, the pointy end should protrude from the hole in the center of the cam. With the poppet valve in place you can now place the lifter in position – the lifter has written on it which side is intended to be place down – its three prongs slot into grooves on the inside of the carburetor body.
Place the small spring into the grooves on the lifter then place the diaphragm over the pointy end of the poppet valve, it should clip in place – the shiny side of the diaphragm should face upwards. Also clip the metal retainer onto the end of the poppet valve – the flat side of the retainer should face down.
Now we can move to the front of the carburetor – inspect the primer cap and ensure there aren’t any cracks or missing pieces (check the primer bulb too). Place the primer o-ring around the sides of the primer cap – as you do look out for any breaks or cracks in the o-ring. Place the small jet into the primer cap with the pointer end down then hook the float in place – when pushing the float up as much as possible the small jet should limit its movement; if this isn’t the case then the jet will need to be replaced.
Move the primer cap and all the bits we have now attached into position in the front of the carburetor body, there is a line on the front of the primer cap which indicates the correct orientation of the primer cap – if the carburetor leaks petrol when reassembling this orientation is the first thing to check. Clean out the main jet and the screw the primer cap in place – gently tighten the main jet so as not to thread the plastic primer cap.
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