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Old 08-16-2010, 11:01 PM   post #1 of 38
slr_65
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Default Assembling the Lawn Boy 107-4607 DuraForce Carb Kit

Hi Guys,

This is my first attempt at a long post on this forum so I hope it goes OK!

First a little background. I was gifted a lightly used 1999 10323 DuraForce powered Lawn Boy. The previous owner said it had started to surge and he'd left gas in it over the winter and wouldn't start. He'd bought a new mower so he gave me this one. Our old mower had shelled out so I was in need of a mower quick and my time is limited so I just wanted to purchase a new carb so it was just a remove and replace operation. Unfortunately you can't just buy a new carburetor already assembled, they've discontinued them. You can however purchase a kit that contains a new carb body and all the pieces so I bit the bullet and bought one of those. I was quite disappointed because all I got was a box of parts - no assembly directions at all, not even a parts diagram! I found the service manual and parts list and set out to rebuild the carb before I'd torn the mower apart (again, I have limited time so I wanted it to be two sessions - one assembling the carb and then later one to remove and replace the carb. So, all I had was the service manual and parts listing to go on as the old carb was still on the mower. I was quite annoyed with the service manual! I've used many service manuals in the past but this one was pretty poor - things like the part names they used didn't match the ones they had on the parts listing, they would tell you to just do something without explaining exactly how to do it (like how to initially set the air vane (governor) collar, or how to install the needle valve clip), not even mentioning things like how to install the choke shaft assembly, etc.. The parts diagram wasn't bad, but they completely forgot to illustrate the pilot jet!

I muddled through and kept some notes - what follows are my notes, I hope they help someone else in the future.

Take care,

Steve

Last edited by slr_65; 08-16-2010 at 11:24 PM.
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Old 08-16-2010, 11:05 PM   post #2 of 38
slr_65
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Default Re: Assembling the Lawn Boy 107-4607 DuraForce Carb Kit

First, I found referencing the parts illustration is quite helpful so here's a copy of it - and I added in the missing pilot jet.
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Old 08-16-2010, 11:06 PM   post #3 of 38
slr_65
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Default Re: Assembling the Lawn Boy 107-4607 DuraForce Carb Kit

Ref # Part# Qty Description
1 95–5581 1 Shaft–Choke
2 94–5788 1 Disc – Choke
3 95–5583 1 Spring–Choke
6 612383 1 Washer
7 98–7001 1 Fuel Nozzle
8 98–1357 1 Jet – Main 77.5
9 94–5787 1 Filter – Fuel
10 95–1899 1 Float & Arm Assembly
11 98–1362 1 Gasket
12 92–9691 1 Chamber–Float
13 608850 4 Screw–HH
14 92–6389 1 Pin
16 92–9697 1 Valve / Seat–Float
18 98–7011 1 Spring–Governor
19 610834 1 Airvane–Collar
20 98–7047 1 Disc–Throttle
21 92–6376 1 Air Vane & Shaft
X1 1 Jet – Pilot (unreferenced in the official shop manual)
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Old 08-16-2010, 11:07 PM   post #4 of 38
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Default Re: Assembling the Lawn Boy 107-4607 DuraForce Carb Kit

[ ] Install the main jet (8) into the fuel nozzle (7) using an appropriately sized flat bladed screwdriver.

[ ] Install the washer (6) onto the fuel nozzle assembly (7 & 8).

[ ] Install the fuel nozzle assembly (6, 7 & 8) into the carburetor body using Loctite 242 blue or equivalent medium strength thread locking compound and an appropriately sized flat bladed screwdriver.

[ ] Install the pilot jet (X1) into the carburetor body using Loctite 242 blue or equivalent medium strength thread locking compound and an appropriately sized flat bladed screwdriver.

[ ] Cut a piece of duct tape or other durable adhesive tape and place it on the carb body over the hole the pilot jet was installed into (the original carburetors had a sticker but no sticker is provided with the kit).

[ ] Install the inlet fuel valve seat (component of 16).into the carburetor body using Loctite 242 blue or equivalent medium strength thread locking compound and an appropriately sized flat bladed screwdriver.

[ ] Install a new inlet valve needle and clip (components of 16) on the float (10).
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Old 08-16-2010, 11:09 PM   post #5 of 38
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Default Re: Assembling the Lawn Boy 107-4607 DuraForce Carb Kit

[ ] Install the float assembly (10 & 16) into the bottom of the carburetor using float hinge pin (14). Ensure that the hinge pin is positioned properly to keep the float level. The float should be free to move up and down easily in the carburetor body.

[ ] Adjust float (10) so the height is 1/2 ± .03” from the bowl flange (gasket not in place) to top of float. The float height is adjusted by carefully bending the brass hinge.
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Last edited by slr_65; 08-16-2010 at 11:34 PM.
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Old 08-16-2010, 11:11 PM   post #6 of 38
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Default Re: Assembling the Lawn Boy 107-4607 DuraForce Carb Kit

[ ] Pressure check the carburetor. If available, attach a pump with a pressure gauge to fuel inlet fitting on carburetor. With carburetor upside down (float up), raise float and lower it to its normal position. Pump pressure to 5 psi. It should hold this pressure indefinitely, but for practical purposes testing for 10 or 15 seconds is sufficient

If a suitable pump is not available then simply blowing into the fuel inlet is usually sufficient.

[ ] Install the fuel filter (9) over the fuel nozzle assembly (6, 7 &8).

[ } Install a new fuel bowl gasket (11) and the fuel bowl (12) with the four bowl retaining screws (13).

[ ] Hook the governor spring (18) into the bottom of the air vane collar (19).
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Old 08-16-2010, 11:15 PM   post #7 of 38
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Default Re: Assembling the Lawn Boy 107-4607 DuraForce Carb Kit

[ ] Install the air vane collar assembly (18 & 19) into the air vane (21). The position of the collar in the air vane is what controls the engine speed and I couldn’t find any instructions in the service manual as to where to initially place it for a DuraForce engine so I held off on this operation until the day I was changing the carb and had the old one handy - I just copied what was on the original carburetor that I was replacing and it worked fine. To copy the original setting I looked at the bottom of the air vane (21) where the air vane collar (19) inserts. I counted the notches from the left side of where the vane attaches to it’s base, it was three.
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Last edited by slr_65; 08-16-2010 at 11:29 PM.
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Old 08-16-2010, 11:16 PM   post #8 of 38
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Default Re: Assembling the Lawn Boy 107-4607 DuraForce Carb Kit

[ ] Install the air vane assembly (18, 19, and 21) into the carburetor body by very carefully pushing the throttle shaft of the air vane into the appropriate hole in the carburetor body. Note the upper portion of the throttle shaft is keyed as is the upper portion of the hole in the carburetor body – the key limits the swing of the air vane (21) to the appropriate 90 degree arc. Make sure the air vane (21) is properly seated into the keyed recess and operates freely with 90 degrees of swing.

[ ] Position the air vane (21) so the slot in it’s throttle shaft is facing out of the carburetor bore (remember to ensure the throttle shaft is fully seated and properly engaged with the keyed portion of the hole in the carburetor body). Push the throttle disc (20) into the throttle shaft slot until it seats (The disc only inserts one way, the flat edge on it should be to the top and there are three locking tabs to secure it on the shaft, two on one side and one on the other - the side with the single locking tab is the one to insert into the throttle shaft slot.).
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Old 08-16-2010, 11:19 PM   post #9 of 38
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Default Re: Assembling the Lawn Boy 107-4607 DuraForce Carb Kit

Once the disc is inserted then again ensure the air vane (21) operates smoothly and has a 90 degree swing. Note that the end of the governor spring (18) that sticks out from between the air vane collar (19) and carburetor body is not attached to anything at this point – it will be attached to the throttle linkage when it’s installed on the lawn mower.

[ ] Install the choke spring (3) onto the choke shaft (1). Some of the choke springs have a straight tail on both ends and may be installed with either end up. Some choke springs have a straight tail on one end and a hook on the other. On the springs with the hook the end with the hook is slid onto the choke shaft (1). In either case the tail is then hooked into the catch on the choke shaft arm.
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Old 08-16-2010, 11:20 PM   post #10 of 38
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Default Re: Assembling the Lawn Boy 107-4607 DuraForce Carb Kit

[ ] Install the choke shaft assembly (1 & 3) into the carburetor body by very carefully pushing the shaft into the appropriate hole in the carburetor body. As you slide the shaft down make sure you hook the lower tail of the choke spring (3) onto the fuel inlet side of the carburetor body.
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Old 08-16-2010, 11:21 PM   post #11 of 38
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Default Re: Assembling the Lawn Boy 107-4607 DuraForce Carb Kit

[ ] Position choke shaft (1) so the slot in it’s shaft is facing out of the carburetor bore. Push the choke disc (2) into the choke shaft (1) slot until it seats (The disc only inserts one way. The disc has a tab cut on one end and this tab goes down. There is also a hole drilled along one edge, this hole goes towards the outer edge of the carburetor bore. There are also three locking tabs, two on one side and one on the other – the side with the single locking tab is the one to insert into the choke shaft slot.).
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Old 08-16-2010, 11:22 PM   post #12 of 38
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Default Re: Assembling the Lawn Boy 107-4607 DuraForce Carb Kit

Once the choke disc (2) is installed check for proper operation of the choke – the spring should keep the choke disc in the open position and the shaft should be able to be rotated against the spring pressure to open the choke without any binding or resistance other than that from the spring.

Congratulations! This completes the assembly of your new carburetor!
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Old 08-16-2010, 11:32 PM   post #13 of 38
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Default Re: Assembling the Lawn Boy 107-4607 DuraForce Carb Kit

There it is guys.

Feel free to post any corrections, tips, whatever.

Take Care,

Steve
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Old 08-17-2010, 05:15 AM   post #14 of 38
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Default Re: Assembling the Lawn Boy 107-4607 DuraForce Carb Kit

Very nice tutorial and photos. Thanks for taking the time and putting it together!
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Old 08-17-2010, 08:58 AM   post #15 of 38
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Default Re: Assembling the Lawn Boy 107-4607 DuraForce Carb Kit

Wow! Illustrated and all! Thanks! This should be long in the archives for future use!

Did the new carb fix all your woes?
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