Disassembly

Model 5200 Carburetor Disassembled:

AIR HORN
1. Remove bowl cover screws and lockwashers.
2. Remove plastic retainer bushings from choke rod. Carefully lift the air horn straight up from the throttle body. Remove the choke rod seal.
3. Remove the float hinge pin, float and inlet needle.
4. Remove the inlet needle seat and gasket.
5. Remove the three enrichment valve vacuum diaphragm screws, washers and diaphragm.
6. Remove three vent cover/solenoid attaching screws and cover.
7. Remove E-clip from vent diaphragm stem and remove diaphragm assembly, vent spring, vent valve retainer and vent valve.

AUTOMATIC CHOKE
1. Remove the choke per the following procedure:
a. Check rivets to determine if mandrel is well below the rivet head. If mandrel is within the rivet head thickness, drive it down or out with a 1/16 inch diameter tip punch.
b. Select a 1/8 inch diameter or No. 30 drill for drilling the rivet heads.
c. Proceed to drill into the rivet head and continue until the rivet head comes loose from the rivet body.

NOTE: Excessive pressure on the drill bit at this point could cause the rivet to spin in the hole.

d. After the rivet head has been drilled off, drive the remaining rivet out of the hole with a 1/8 inch diameter punch. If this procedure is followed, the hole size is retained.
e. After the above steps have been completed on the remaining rivet, remove remaining standard screw.

2. Remove the retaining ring, thermostatic housing and plastic index plate as a unit to avoid damage too the bimetal coil.
3. Remove the choke housing assembly screws.

Note: The long screw goes in the long leg of the assembly.

Slip the housing away from the main body and disengage the fast idle rod. Remove the O-ring from the passage.
4. Remove the choke lever spring shaft nut and lockwasher, choke lever and fast idle cam.
5. Remove the three choke pulldown diaphragm cover retaining screws.
6. Remove the cover, return spring, diaphragm and rod assembly.

ACCELERATOR PUMP
1. Remove the four pump cover screws and pump cover assembly. Remove the pump diaphragm assembly and pump return spring.
2. Remove pump discharge nozzle screw assembly and pump discharge nozzle and two gaskets. Remove two pump discharge check balls. (See Figure)

MAIN BODY
1. Remove primary high speed bleed and main well tube.
2. Remove the secondary high speed bleed and main well tube, and note the size of the air bleed plugs and main well tubes so they may be reinstalled in the correct position.
3. Remove the primary and secondary main metering jets, and note the different size jets so they may be reinstalled in the correct position.
4. Remove the enrichment valve, needle, seat and spring assembly. Remove the secondary idle jet retainer and idle jets located on the side of the carburetor body.
5. Remove the tamperproof idle mixture concealment plug by center punching and drilling a 3/32 inch diameter hole through the hardened steel plug. Install an easy-out into the hole and remove the plug.
6. After removing the plug, count and record the number of turns required to lightly seat the idle adjustment needle. Count to the nearest 1/16th turn. Remove the idle needle and spring.
7. Remove the secondary operating lever return spring, throttle positioner and bracket.
8. Remove the throttle stop adjusting screw plastic limiter cap (if equipped), by carefully prying with a thin blade screwdriver, and then remove the throttle screw.
9. Remove the primary throttle shaft nut, lockwasher, flat washer and accelerator pump cam.