AISEN Carburetor Repair Rebuild Kit Instruction Manual

1. Introduction

This manual provides essential instructions for the proper use and installation of the AISEN Carburetor Repair Rebuild Kit. This kit is designed to restore the functionality of Tillotson HK carburetors found in various Sachs Dolmar chain saws and other compatible equipment. By following these guidelines, you can effectively replace worn components and ensure optimal performance of your carburetor.

2. Safety Information

Always prioritize safety when working with power tools and fuel systems. Failure to follow safety precautions can result in serious injury or damage to equipment.

• Ensure the engine is completely off and cooled down before beginning any work.
• Disconnect the spark plug wire to prevent accidental starting.
• Work in a well-ventilated area to avoid inhaling fuel fumes.
• Wear appropriate personal protective equipment, including safety glasses and gloves.
• Handle fuel and carburetor cleaner with care, as they are flammable and can cause skin irritation.
• Keep a fire extinguisher nearby.
• If you are unsure about any step, consult a qualified technician or the original equipment service manual.

3. Package Contents

The AISEN Carburetor Repair Rebuild Kit includes various components necessary for a comprehensive carburetor overhaul. Please verify that all parts are present and undamaged before proceeding with installation.

Image 3.1: Overview of the AISEN Carburetor Repair Rebuild Kit components, including gaskets, diaphragms, needles, springs, and screens.

Typical contents include:

• Metering Diaphragm
• Pump Diaphragm
• Gaskets (various shapes and sizes)
• Inlet Needle and Lever
• Inlet Spring
• Fuel Filter Screens
• Check Valves (if applicable)
• Other small hardware (e.g., screws, pins)

4. Compatibility

This repair kit is designed to replace Tillotson carburetor rebuild kits RK-32HK and RK-34HK. It is compatible with various Sachs Dolmar chain saws and other equipment utilizing Tillotson HK series carburetors. Please verify your carburetor model before installation.

Known Compatible Models:

• Sachs Dolmar Chain Saws: HK-9 118, HK-13 HK-37 117 119, HK21 112 113 114
• Models 034AV, 034EC, 038 (with Tillotson HK carburetors)
• Tillotson HK Carburetor Series: HK-7, HK-7B, HK-7C, HK-9A, HK-9B, HK-9C, HK-10C, HK-10D, HK-10E, HK-12A, HK-12B, HK-12C, HK-15B, HK-15C, HK-16D, HK19A, HK-19C, HK-20A, HK-20B, HK-20C, HK-21, HK-23A, HK-23B, HK-23C, HK-23D, HK-23E, HK-27B, HK-28C, HK-29, HK-38A, HK-404A, HK-13A thru D, HK-21B, C, HK-30A, HK-37A, HK-40B

5. Installation Guide (Carburetor Rebuild)

This section outlines the general steps for rebuilding a Tillotson HK carburetor using the AISEN repair kit. Specific disassembly and reassembly procedures may vary slightly depending on your exact carburetor model. Always refer to your equipment's service manual for detailed instructions and torque specifications.

5.1. Preparation

1. Clean Work Area: Ensure a clean, well-lit workspace to prevent contamination and loss of small parts.
2. Gather Tools: You will need screwdrivers, pliers, a small pick, carburetor cleaner, and possibly a small container for parts.
3. Remove Carburetor: Carefully remove the carburetor from the engine, noting the connections for fuel lines, throttle linkage, and choke.
4. Drain Fuel: Drain any remaining fuel from the carburetor into an approved container.

5.2. Disassembly and Cleaning

1. Disassemble Carburetor: Carefully remove all covers, diaphragms, gaskets, and internal components. Pay close attention to the order and orientation of each part. Take photos if necessary.
2. Inspect Components: Examine all removed parts for wear, damage, or corrosion. Note any components that will be replaced by the kit.
3. Clean Carburetor Body: Use carburetor cleaner to thoroughly clean all passages, jets, and the carburetor body. Ensure all debris, varnish, and fuel residue are removed. Use compressed air to blow out passages, ensuring no blockages remain.
4. Clean Small Parts: Clean any reusable small metal parts (e.g., throttle shaft, choke shaft) with carburetor cleaner.

Image 5.1: Various gaskets and diaphragms included in the kit, essential for sealing carburetor chambers.

5.3. Reassembly with New Parts

Replace all worn or damaged components with the new parts from the AISEN kit. Refer to your disassembly notes or photos for correct placement.

1. Install Inlet Needle and Lever: Replace the inlet needle, lever, and spring. Ensure the lever height is correctly set according to your service manual (often flush with the carburetor body or slightly below).
2. Install Fuel Filter Screens: Replace any old fuel filter screens with new ones.
3. Install Diaphragms and Gaskets: Carefully place the new gaskets and diaphragms in their correct positions. Ensure they are not pinched or misaligned. The metering diaphragm typically goes on first, followed by its gasket and cover. The pump diaphragm and its gasket follow a similar pattern.
4. Secure Covers: Reinstall all covers, tightening screws evenly to prevent warping. Do not overtighten.
5. Final Checks: Before reinstalling on the engine, visually inspect the carburetor for any missing parts or incorrect assembly.

Image 5.2: Small metal components such as the inlet needle, spring, and fuel filter screens, crucial for fuel flow regulation.

5.4. Reinstallation and Adjustment

1. Reinstall Carburetor: Mount the rebuilt carburetor back onto the engine, reconnecting fuel lines, throttle linkage, and choke. Ensure all connections are secure and leak-free.
2. Initial Adjustments: Most carburetors have high and low-speed adjustment screws. As a starting point, gently turn both screws clockwise until they lightly seat, then back them out 1 to 1.5 turns counter-clockwise. These are preliminary settings.
3. Start Engine and Fine-Tune: Start the engine and allow it to warm up. Adjust the idle speed screw for a stable idle. Then, fine-tune the high and low-speed mixture screws according to your equipment's service manual for optimal performance and responsiveness.

6. Maintenance After Rebuild

Proper maintenance after a carburetor rebuild is crucial for longevity and performance.

• Use Fresh Fuel: Always use fresh, properly mixed fuel (if applicable for 2-stroke engines). Stale fuel can quickly clog carburetors.
• Fuel Stabilizer: If storing the equipment for extended periods, use a fuel stabilizer or drain the fuel system completely.
• Air Filter: Regularly clean or replace the air filter to prevent dirt and debris from entering the carburetor.
• Fuel Filter: Inspect and replace the in-tank fuel filter periodically.

7. Troubleshooting

If you encounter issues after rebuilding your carburetor, consider the following common problems and solutions:

If troubleshooting steps do not resolve the issue, it is recommended to consult a professional service technician.

8. Specifications

• Product Name: AISEN Carburetor Repair Rebuild Kit
• Compatible Carburetor Series: Tillotson HK
• Replaces Kits: RK-32HK, RK-34HK
• Package Dimensions: 3 x 2 x 1 inches
• Item Weight: 0.493 ounces
• Manufacturer: AISEN