How to Rebuild Your Vespa large Frame Carburetor step by step:
Intro and Part 1) Pulling your Carburetor to your Vespa.
Part 1 of 5.
Carburettor DELL`ORTO SI 24/24
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Part I: Removal
Before getting started on any mechanical job, it's always best to prep your working area and have the tools you might need pulled and ready for use. For the removal part of this job you should have the following tools ready and on hand so that you can successfully pull the carburetor from your vintage Vespa. You will need:
Bladed & Philips head Screw Drivers
Socket Wrench w/8mm, 10mm & 11mm heads and a small 2 inch spanner.
Small Needle nose pliers
Small rag.
Optional:
A matt of some sort -- after all, who wants to be on the hard ground?
A) Let's get started here by pulling the right side cowl. You'll of course want to remove the cowl in order to expose the engine and carburetor airbox on top of the engine. Now that you have the cowl removed you'll want to place the cowl aside and out of the way so that it isn't kicked and damaged while you work on your carburetor and engine.
B) The next up you'll want to remove the airbox box top. To do this, you can use either a bladed screwdriver or an 8mm socket wrench. Start by simply un-screwing the two hex screws found at either end of the airbox. Now place the airbox top within arms reach, as you'll want to use it to temporarily sore all bolts and parts that you're removing.
C) Now that you've removed the airbox top, you'll want to remove air filter. For this part of the job you'll need a bladed screwdriver. Start by fully Un-screwing the two flush screws on top of the filter that fit nearly-flush with the airfilter, but not the long one.
D) The next step is to disconnect the fuel line to the carburetor. Start by finding the fuel "banjo", which is located at the front of the carburetor. To remove this, you can use either a bladed screwdriver or 10mm socket wrench to unscrew this from the carburetor. Personally I would recommend the 10mm socket wrench with spanner for this, it's easier to use here, but if you're on the side of the road doing this repair, by all means use bladed screwdriver. You'll start by loosening the banjo to the point where it disconnects.
E) The next step here is to remove the choke cable. First you can locate it by finding the only cable with the small loop on the end on the front of the carburetor; it should connected via a small actuating leaver. Now use a bladed screwdriver to open the actuating, this should allow access to the metal choke wire to be pulled free of the actuating lever. Now with the help of those needle nose pliers you should be able to free the cable from the choke actuating leaver.
F) Now you're now nearly ready to pull the carburetor out of the airbox. But first locate the 2 special nuts that attach the carburetor to the airbox. Simply look for the two 11mm black bolts on either side of the carburetor. To unscrew these, you'll use 11mm socket on a small spanner. Start by loosening each bolt slowly and as equally as you can. I do this by turning them each bolt ¼ turn then going back and forth between the two bolts. The reason behind losing them this way is that having one bolt really tight and the other really lose can increase changes of warping the body of the carburetor. Anyway, as each bolt becomes lose you should be able to hand loosen them till they detach from the airbox. (Note - No need to remove the bolts once they are unattached, as you will pull them and the carburetor out as one unit). If you do pull the special nuts off at this point, make sure to secure the washers. You don't want them to fall into the motor.
G) With your left hand, grip the top of the carburetor and lift upwards. The carb should come free with ease.
H) Lastly, stick a rag in the bottom of the airbox. This should keep anything from accidentally being dropped into the now exposed hole in your engine. Trust me, you don't want to find out later that you dropped a washer of bold down there.
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