Carbon Canister Kit

Note: Retain all removed parts for later installation unless otherwise noted.

1. Park the machine on a level surface, shift the transmission into the NEUTRAL position (manual) or the PARK position (automatic) and engage the parking brake.

2. Shut off the engine, remove the key (if equipped), disconnect the battery, and allow the engine to cool.

3. Tilt the passenger seat forward and align the prop rod into the detent in the prop-rod-guide slot.

4. Drain the fuel tank; refer to your machine Operator’s Manual.

5. Remove the 4 screws securing the cover and remove it (Figure 1).

   Note: You may discard the cover.

   

   Figure 1

   1. Screw (#10 x 3/4 inch)
   2. Cover
   3. Fuel tank

6. Under the cover, place the bushing as shown in Figure 2 and mark the center on the fuel tank.

   

   Figure 2

   1. Place the bushing here and mark the center.

7. Remove the fuel pump from the machine; refer to your machine Operator’s Manual .

8. Insert a rag inside the tank through the opening for the fuel pump to catch any debris.

9. Drill a 17/32 inch diameter hole in top of the fuel tank at the location marked in step 7 and clean up the opening and remove the rag and any debris.

Parts needed for this procedure:

1. Assemble the carbon canister, canister clamp, and 2 grommets (9/16 inch) to the canister bracket (Figure 3)

   Note: Ensure that the inlets on the canister face the front of the machine and point down.

2. Route a 10-1/2 inch hose through the bracket to the center canister inlet marked TANK and secure it with a hose clamp (1/2 inch).

3. Route the 25 inch hose through the bracket to the outer canister inlet marked PURGE and secure it with a hose clamp (13/32 inch).

4. Install the bushing to the hole drilled in Preparing the Machine.

5. Install the canister bracket assembly with the screws removed in Preparing the Machine

   

   Figure 3

   1. Use the previously removed screws.
   2. Carbon canister
   3. Canister clamp
   4. Canister bracket
   5. Connect the 10-1/2 inch hose to the canister inlet marked TANK and secure it with a 1/2 inch hose clamp.
   6. Connect the 25 inch hose to the canister inlet marked PURGE and secure it with a 13/32 inch hose clamp.
   7. Grommets (9/16 inch)
   8. Elbow fitting
   9. Bushing
   10. Large end of straight fitting (3/16 to 1/4 inch)

6. Connect the free end of the 25 inch hose to the small end of a straight fitting (3/16 to 1/4 inch) with a hose clamp (13/32 inch).

7. Connect the free end of the 10-1/2 inch hose from the canister to the small end of the elbow fitting with a hose clamp (1/2 inch).

8. Connect the large end of the elbow fitting to the bushing.

Parts needed for this procedure:

1. Assemble 4 grommets (1/2 inch) to the valve bracket.

2. Route 2 hoses (10-1/2 inches) through the 2-hole tab on the valve bracket to the 2 large inlets on the vacuum-control valve.

3. Secure the hoses to the vacuum-control valve with hose clamps (1/2 inch).

4. Connect the loose end of the lower hose on the vacuum-control valve to the straight fitting on the end of the 25 inch hose and secure it with a hose clamp (1/2 inch).

5. Connect the loose end of the upper hose on the vacuum-control valve to the small end of the straight fitting (1/4 to 5/16 inch) and secure it with a hose clamp (1/2 inch).

   

   Figure 4

   1. Small end of straight fitting (1/4 to 5/16 inch)
   2. Hose clamp
   3. Support bar extending from frame.
   4. Valve bracket
   5. Grommet (1/2 inch)
   6. Connect 2 hoses (10-1/2 inches) to the vacuum control valve.
   7. Vacuum-control valve
   8. Connect lower hose on the vacuum-control valve to the straight fitting on the 25 inch hose.
   9. Hose clamp (1/2 inch).

6. Route the 9 inch hose through the 1-hole tab on the valve bracket to the remaining inlet on the vacuum-control valve.

7. Secure the 9 inch hose to the vacuum-control valve with a hose clamp (13/32).

8. Connect the loose end of the 9 inch hose to the small end of a straight fitting (3/16 to 1/4 inch) with a hose clamp (13/32 inch).

9. Secure the valve bracket assembly to the support bar that extends from the frame with a cable tie (Figure 5).

   

   Figure 5

   1. Hose clamp (13/32 inch)
   2. 9 inch hose
   3. Cable tie
   4. Small end of straight fitting (3/16 to 1/4 inch)

Parts needed for this procedure:

1. Connect the 10-1/2 inch hose to the straight fitting on the 9 inch hose from the vacuum-control valve and secure it with a hose clamp (1/2 inch).

2. Connect the loose end of the 10-1/2 inch hose to the center branch of the 1/4 x 1/4 x 1/4 inch T-fitting and secure it with a hose clamp (1/2 inch).

3. Connect the 9-1/2 inch hose to the straight fitting on the upper hose from the vacuum-control valve and secure it with a hose clamp (5/16 inch).

4. Connect the loose end of the 9-1/2 inch hose to the center branch of the 1/2 x 1/2 x 5/16 inch T-fitting and secure it with a hose clamp (5/16 inch).

   

   Figure 6

   1. 1/2 x 1/2 x 5/16 inch T-fitting
   2. Hose clamp (5/16 inch)
   3. 9-1/2 inch hose
   4. 1/4 x 1/4 x 1/4 inch T-fitting
   5. Hose clamp (1/2 inch)
   6. 10-1/2 inch hose

5. Position the 1/4 x 1/4 x 1/4 inch T-fitting along the short PCV hose extending from the top of the engine and cut the hose where appropriate to install the T-fitting.

   Note: Cut the PCV hose about 3 inches away from its connection to the engine.

6. Connect the 1/4 inch branches of the T-fitting to the cut ends of the PCV hose with hose clamps (1/2 inch) as shown in Figure 7.

7. Position the 1/2 x 1/2 x 5/16 inch T-fitting along the long vacuum hose extending from the top of the engine and cut the hose where appropriate to install the T-fitting.

   Note: Cut the PCV hose about 10-1/2 inches away from itsconnection to the engine.

8. Connect the 1/2 inch branches of the T-fitting to the cut ends of the vacuum hose with hose clamps (13/16 inch) as shown in Figure 7.

   

   Figure 7

   1. Connect the 1/2 inch branches of the T-fitting into the cut vacuum hose.
   2. Connect the 1/4 inch branches of the T-fitting into the cut PCV hose.

9. Install the new fuel cap to the fuel tank.

10. Connect the battery and fill the fuel tank; refer to your machine Operator’s Manual.