DA-100, 120, 200 Carb Rebuild

Carburetor Rebuild - DA-100, 120, 200

Your DA-100, DA-120, or DA-200 carburetor can be rebuilt in just a few minutes using a Phillips-head screwdriver, carburetor cleaner, and a standard hobby knife.

1. The Walbro D10-WJ kit is required to rebuild your 100, 120, or 200 carburetor. 

2. Remove the 4 Phillips-head screws to remove the red anodized diaphragm plate to access the diaphragm. Note: The 200 carburetor, as well as the older 100 and 120 carburetors, will have a silver diaphragm plate. 

3. Peel back the diaphragm from the gasket on the carb body. If the diaphragm feels like paper, it is time to replace it. If the diaphragm is soft and rubbery, it is fine to re-use. Generally if you tear down the carburetor to this point, it's best to use a new diaphragm.

4. Put your thumb over the metering needle lever to secure it in place, and carefully remove the Phillips-head screw. CAUTION: The metering lever has a spring behind it, slowly remove the metering lever/needle assembly to avoid losing the spring. 

5. Turn the carb around and remove the rear plate by unscrewing the 4 Phillips-head screws.

6. Remove both the gasket and the neoprene check valve flapper gasket. 

7. Carefully remove the mesh filter screen from inside of the carb body using a hobby knife with a good point, ensuring not to damage the mesh filter screen. 

8. Using carb cleaner with a precision straw, spray into all passages of the carburetor to clean out any debris that may be inside of the carburetor. Make sure you clean any debris off the mesh filter screen as well. 

9. Re-install the mesh filter screen using the back of your hobby knife ensuring it is fully seated inside of the carb body. 

10. Re-install the check valve flapper gasket to the rear carb plate ensuring it is aligned with the molded alignment pins. 

11. Re-install the neoprene check valve flapper over the top of the gasket ensuring it is aligned with the molded alignment pins. 

12. Secure the pump cover and gasket/check valve flapper assembly to the carburetor body with the 4 Phillips-head screws ensuring they are good and snug. 

13. Place the metering needle and spring back into their respective locations. 

14. The metering needle lever needs to be re-installed with the metering needle fork hooked to the metering needle, the spring sitting on the spring perch on the metering lever, and the rod inserted into the metering needle lever. 

15. Use your finger to hold the metering needle lever assembly in place to avoid losing the spring and metering needle. 

16. A magnetized Phillips-head screwdriver is a handy tool to hold the Phillips-head screw while you re-insert it into the threaded passage in the body of the carburetor. 

17. Tighten the screw down over the rod to secure the metering needle/lever assembly. 

18. Re-install the diaphragm gasket to the carburetor body ensuring it is aligned with the molded alignment pins. CAUTION: Lay the diaphragm itself over the gasket, ensuring to hook the diaphragm to the metering needle and ensuring the gasket is aligned with the molded alignment pins. This step is critical to ensuring your carburetor pumps fuel as designed. 

19. Re-install the 4 Phillips-head screws on the diaphragm cover ensuring they are good and snug.