1. Excessive Clearance Between Internal and External Rocker Arms
(1) Use of Gaskets for Inner and Outer Rocker Arms
Gaskets can be made from sheet metal, copper, iron wire, or semi-circular opening pins. During installation, ensure there is a small gap between the inner and outer rocker arms, and wrap the gasket around to prevent it from falling out.
(2) Check the Thickness of the Gasket
Insert your hand into the mounting hole of the fuel pump cylinder, manually rotate the engine's crankshaft slowly, and feel the camshaft position that is not in contact with the fuel pump. Install the fuel pump (after installing the gas pump and cylinder liner). Tighten the bolts slightly, then manually push the pump into place. If there is suction effect, the gasket is too thick and needs adjustment.
2. Broken Rocker Arm
If the rocker arm breaks, you can use one of the following methods:
(1) Tie a wire or string to the fuel pump arm and fix the other end inside the cabin. Control it manually, allowing the vehicle to drive at low speed only.
(2) If a small pulley is available, the wire or string can be tied to the accelerator pedal via the pulley and controlled by foot.
(3) Remove the broken rocker arm and find a choke or throttle pull tube. Secure one end to the hand pump handle and the other to the wiper lever. By turning on the wiper switch, the lever will move back and forth, enabling the pump to draw fuel.
(4) For electric wipers, remove the wiper assembly, attach it to the top of the fuel pump, and secure both ends to the handle and wiper lever. Use the wiper motor to swing the lever, which will help operate the hand pump.
Choose the method based on your situation at the time.
3. Ruptured Pump Diaphragm
(1) If the diaphragm is only slightly damaged, such as a torn edge, separate the damaged part from the good one and reassemble.
(2) If the diaphragm has a long crack, cut a piece of plastic, tarp, or film to fit the original shape and sandwich it between the layers.
(3) If fuel is leaking into the crankcase, the oil becomes diluted. Replace it with new oil. If not available, drain the old oil, heat it to evaporate the gasoline, and use it temporarily after cooling.
4. Poor Sealing of Inlet and Outlet Valves
(1) If the bakelite valve is uneven, flip it over for continued use, or grind the uneven surface using abrasive paste on glass. Ensure the valve is smooth before reinstalling.
(2) If valves are sealed due to gumming, clean them with alcohol, high-concentration white spirit, or acetone.
(3) If the valve is ruptured, replace it with a thin piece of glass. Soak the glass in water, then use pliers to shape it into the correct form. Press it flat on a heater to strengthen the bond.
5. Cracked Oil Cup
(1) If the oil cup is only cracked, repair it using old plastic, like a toothbrush handle. Clean the cup thoroughly, heat the plastic on the exhaust pipe (avoid oil contamination), melt it, and press it into the crack. Let it cool and flatten it for better adhesion.
(2) If the cup is completely broken, replace it with an alternative like a bottle, thermos cover, drink box, bamboo, small cup, flashlight cap, or cream bottle. If the substitute is too short, add a spacer pad and secure it with screws.
To modify a bottle, wrap it with cotton thread, ignite the thread, and quickly submerge it in cold water. The bottle will collapse and break at the wrapped area.
If the oil cup has a central partition, cut a soft board to match the size and install it in the original position.
6. Worn External Rocker Arm and Cam
If the external rocker arm and cam are worn and the fuel pump is too small, consider thinning or removing the cylinder liner (without causing oil leaks).
7. Broken Pump Spring
If the pump spring breaks, use a steering wheel horn button spring or another similar spring as a replacement.
8. Fuel Leaks
(1) If the liner is stiff and not sealing well, soak it in hot water to soften it, then apply grease and reuse.
(2) If the above method doesn’t work or the liner is ruptured, cut a piece of yellow paper or asbestos board to the original size and use it as a substitute.
9. Gas Pump "Vapor Lock" Phenomenon
To eliminate vapor lock:
(1) Turn off the engine and open the hood to ventilate.
(2) Rinse the tubing with cold water to cool it down (avoid getting water on intake, exhaust pipes, or fuel pump cup).
(3) Place a cloth soaked in cold water on the fuel pump and let it cool for a while. Then remove the carburetor and manually pump the fuel several times (without sending it into the engine).
(4) If the temperature is high and vapor lock occurs frequently, place a wet sandbag over the pump to block heat from the exhaust. Keep the sandbags wet for better insulation.
10. Damaged Fuel Pump
If the pump is damaged and not working, use a container filled with gasoline, install it above the carburetor, and connect it with tubing to create a gravity-fed fuel system.
Be cautious of fire hazards when using this method.
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