Mark-3 Service Manual

MARK-3
Portable 4-Stage Fire Pump

Instruction & Service Manual
MARK-3 Service Manual
www.wildfire-env.com 1-800-426-5207
Pump Clamp
Throttle
Muffler
Digital Overspeed Switch

(DOS)
Spark Arrestor
Choke Lever
Priming Inlet
Air Filter
Electronic Ignition Module
Discharge Outlet
Suction Inlet
11/2012
Fuel Supply Hose Connect
TABLE OF
CONTENTS
General Information
Page
Major Overhaul Service
Page
SPECIFICATIONS
ENGINE OVERHAUL SERVICE PROCEDURE
37
SERIAL NUMBERS
DISASSEMBLY PROCEDURE FOR ENGINE
38
REASSEMBLY SERVICE FOR ENGINE

Engine Operating
STARTER
OPERATING INSTRUCTIONS
THE IMPORTANCE OF PROPER
FUEL MIXTURE
39-40
DISASSEMBLY PROCEDURE FOR PUMP END

6
ASSEMBLY PROCEDURE FOR PUMP END
41
42-43
6-7
Miscellaneous
8-11
FRAME
44
FLOODING
12
QUICK-CONNECT FUEL LINE
44
COLD WEATHER
12
NOISE REDUCTION MUFFLER
45
TROUBLESHOOTING CHART
13
DECARBONISING
45
ELECTRONIC IGNITION
14
Technical Specifications
Pump Unit
TORQUE VALUES
46
PUMP OPERATION AND LUBRICATION
14
CYLINDER SPECIFICATIONS
46
PUMP TEST KIT
16
CLEARANCE DATA AND LIMITS
46
PUMP ADJUSTMENTS
16
SOLID STREAM NOZZLES
46
DIGITAL OVERSPEED SWITCH (DOS)
17
MAXIMUM PERFORMANCE VALUES
46
METER HEAD OF WATER AND

EQUIVALENT PRESSURE
46
Regular Maintenance
MAINTENANCE CHECK LIST
19
SERVICING SPARK PLUG
20
Appendices
UPGRADED SPARK PLUG CAP
20
ELECTRONIC IGNITION UNIT
21
ELECTRONIC IGNITION, CONVERSION

INSTRUCTIONS (POINT TO CDI)
ELECTRONIC IGNITION MODULE SETTINGS
22
DECOMPRESSION SWITCH R-233DS
23
SERVICING CARBURETOR
24-26
CARBURETOR TROUBLESHOOTING CHART
27
AIR FILTER & CYLINDER ASSEMBLY
28
COOLING SYSTEM
29
THE REWIND STARTER
30-34
MAGNETO
35-36
ELECTRONIC IGNITION, INSTALLATION

INSTRUCTIONS
53
MECHANICAL CUT-OUT SWITCH
54
STOP SWITCH KIT
55
DOS INSTALLATION INSTRUCTIONS

IGNITION TIMING TOOL
Parts Index
Warranty
11/2012
47-52
55-59
60
61-64
67
GENERAL
INFORMATION
This handbook
includes
specifications,
performance data,
operating instructions,
normal servicing
information and parts
list for the MARK-3
centrifugal fire pump
unit.The MARK-3 unit
has been designed
to meet all the
requirements of
advanced techniques
in forest fire control,
including USDA Forest
Service Specifications
No. 5100-274C. This
versatile unit enables
the pump to be used
for high pressure
and volume (B-2
volume Pump End
interchangeability).
It is also suitable for
rural and municipal
fire protection, or
wherever a large
volume of water or
high pressure is
required. Tandem
operations enable to
move water over
greater distances or
higher altitudes.
SPECIFICATIONS
The MARK-3 pump end (12-16 / 12-16S) is an anodized horizontal 4-stage centrifugal precision built
pump. Both the 2 (51 mm) NPSH* male suction connection and 1 1/2 (38 mm) NPSH male
discharge connection are made to standard forestry thread specifications.
The MARK-3 engine is a one-cylinder, two-cycle, air-cooled engine incorporating ball and roller
bearings. The unit is also equipped with a rewind pull-cord starter and automatic cutout switch.
*NPSH stands for straight pipe threads also abbreviated by IPT or SIPT.
WARNING
The improper use of this pump could result in serious injuries.
Please read the manual before using your MARK-3 pump unit.
Always wear eye and ear protection when operating the pump unit.
DANGER
DANGER
Be careful, never touch the muffler, as it can reach very high temperatures and cause serious burns.
Always allow enough time after stopping the unit for the muffler and surrounding parts to cool down.
Always use proper fuel mixture to ensure suitable lubrication.
CHARACTERISTICS
Complete unit
59.8 lbs
27.1 kg
Height
16
41 cm
Width
12
31 cm
Length
23
58 cm
Pump end only
15 lbs
6.8 kg
Max. engine power
10 HP
7.46 kW
Carburetor
Tillotson all position diaphragm type with integral fuel pump and filter
Ignition system
Ducati Electronic Ignition
Spark plug*
Bosch M4AC, NGK A8
Fuel consumption
4.5 L/hr (1.2 US gal/hr)
* For MARK-3 engines that use 14 mm spark plugs we recommend:

Bosch W4AC, NGK B8HS, Champion L82C
MAXIMUM PERFORMANCE
Pressure
Discharge Flow
psi
kPa
bar
US GPM
IMP GPM
L/min
98
82
371
50
345
3.45
89
74
337
75
517
5.17
83
69
314
100
690
6.90
78
65
295
150
1034
10.34
65
54
246
200
1379
13.79
52
43
197
250
1724
17.24
38
32
144
300
2069
20.69
25
21
95
350
2413
24.13
34
380
2620
26.20
11/2012
400
300
2068
200
689
1379
100
PSI
kPa
GENERAL
INFORMATION
2758
MK-3
Maximum Pressure: 380 PSI
(2620 kPa)
Free flow: 98 US gals/min
(370 L /min)
Maximum Head: 878' (268 m)
MK-3
MK-3-B2
Maximum Pressure: 155 PSI
(1068 kPa)
Free flow: 180 US gals/min
(681 L /min)
Maximum Head: 358' (109 m)
MK-3-B2
US gals/min
50
100
150
200
L /min
189
379
568
758
24:1
READ ME FIRST
Good lubricating is important. Use a high quality
API-TC certified 2-cycle oil in preparing the gas/oil
mixture (24:1). Always allow the engine to warm-up
for at least 2 minutes before using full throttle. DO
NOT run engine with pump disconnected or dry pump.
1.1
1.2
SERIAL NUMBERS
Pump end serial number is located on the side of the pump (1.1).
Engine serial number is stamped on a nameplate attached to the crankcase (1.2).
These serial numbers are the key to various design details pertaining to the original manufacture
of each unit. Therefore, it is very important to specify serial numbers whenever ordering
parts and tools or when requesting information.
1.3
DIRECTIONAL REFERENCES
All references to right side and left side of unit are made as they appear to operator when facing
rewind starter, thus the carburetor is on the right side and the muffler is on the left side.
11/2012
Viewed in this manner (facing the recoil starter), the engine will rotate in a clockwise direction (1.3).
ENGINE
OPERATING
TIP
If the rewind starter should
break while the unit is on
the fire line, the complete
rewind starter assembly can
be easily removed, thereby
gaining access to a manual
starter pulley which is
mounted on the flywheel.
Using a rope, wrap around
starter pulley and pull.
Make sure rope wrapping
will ensure clockwise
rotation (from starter view).
CAUTION
Not enough emphasis can
be placed on the use of
correct gasoline and oil
mixture. Using less than the
recommended portion of oil
will cause overheating and
possible engine damage.
Using more than the
recommended proportion of
oil will cause spark plug
fouling, erratic carburetion,
excessive exhaust smoke
and rapid carbon deposits.
FOR TROUBLE FREE OPERATION
DO NOT run engine at full speed until thoroughly warmed up.

DO NOT lift strainer out of the water while pump is operating.
DO NOT run engine with pump disconnected.
DO NOT run pump when dry.
Check strainer frequently to make sure that it is not clogged with moss, leaves, etc.
DO NOT use suction hose without footvalve strainer.
Remove and drain pump after final use.
STARTER
The starter is an automatic rewind type. A proper operating technique will add many hours of life to
the starter rope and starter.
Grasp handle firmly and pull slowly until resistance (past compression), then continue to pull with a
short, vigorous stroke. Pulling handle sideways causes excessive wear. If kickback occurs, let go of
handle immediately.
When engine starts, retain grip on handle and allow rope to rewind slowly.
Note: The rope should be replaced when wear is apparent.
See rewind starter Servicing and Parts (page 31).
OPERATING INSTRUCTIONS
Oil: API-TC certified 2-cycle mixing oil.
Gas: Unleaded 87 octane.
Mixing ratio: 24:1. Mix 24 parts of gasoline with 1 part of two-cycle oil.
(Do not use gasoline that has a concentration of ethanol that is higher than 10%).
Do not use poor quality oil, high detergent oil or oil with solid additives (graphite, moly, T.F.E., etc.).
Too much emphasis cannot be placed on the use of correct gasoline and oil mixture.
MIXTURE RATIO
Oil
Gasoline
1 L (0.22 IMP gal, 0.26 US gal)
24 L (5.3 IMP gal, 6.3 US gal)
1 US Quart (0.95 L)
6 US gals (5 IMP gal, 22.75 L)
CONTROLS
1
2
There are only 3 controls which are used for normal operation: (1.4)
1 DOS (Digital Overspeed Switch)
2 Throttle lever
3 Choke lever
24:1
11/2012
1.4
ENGINE
OPERATING
TO START MARK-3 UNIT

1. Fill fuel supply tank with recommended fuel mixture.
2. Connect fuel supply line to fuel supply tank (1.5).
3. Attach fuel supply line to the adaptor located on right side of engine frame. Pump fuel to fill
supply line (1.6).
DO NOT use suction hose without footvalve strainer. DO NOT allow footvalve strainer to
rest on bottom of lake or riverbed.
4. Connect footvalve strainer to male end of suction hose, then fill suction hose with water and
connect to pump. 1 Use universal hose coupling wrench to tighten coupling firmly (1.8).
5. Connect discharge hose 2 , nozzles, etc., to pump. Use a rope or other means to keep strainer
at proper height, approximately 30 cm (1 foot) below water surface. If strainer is too close to
the water surface, it will draw air and pump may lose prime.
6. Fill pump with water manually or using a hand primer (B-5980), then reinstall priming cap and
tighten firmly (1.8).
1.5
7. Move throttle lever to "Start" and "Warm up" position (approx. 3 increments).
8. Close choke, if engine is cold.
9. Slowly turn engine until resistance (past compression).
10. Give starter rope several quick, steady pulls until engine coughs.
11. Open choke slightly and pull starter rope until engine runs.
12. Slowly open choke and allow engine to warm up for at least 2 minutes before using full throttle.
The MARK-3 engine was initially run-in at the factory. Full throttle operation can be used
provided the engine is given a thorough warm-up period beforehand.
1.6
Important: Failure to allow the engine to warm up may lead to piston scoring and possibly
more serious damage.
DIGITAL OVERSPEEED SWITCH (DOS)
The MARK-3 unit is equipped with a digital overspeed switch. This safety device will stop the
engine instantly and thereby eliminate overspeeding.
When the DOS automatically stops the engine, this is a warning that there is a problem. Do not
restart the engine until cause of trouble has been identified and corrected.
1.7
TO STOP MARK-3 UNIT

1. Move throttle lever to "Stop" position.
2. Allow unit to run for approximately 1 minute with throttle in this position.
B-5980
3. Press and hold "OFF" button on the DOS until the engine shuts down.
4. Remove and drain pump after final use.
1
2
11/2012
1.8
ENGINE
OPERATING
THE IMPORTANCE OF FUEL / MIXTURE RATIO, AIR / FUEL

RATIO AND OIL CONSIDERATIONS
FUEL MIXTURE RATIO

The ratio amount of gasoline to
2 cycle mixing oil can be classified
as either Rich or Lean.
RICH MIXTURE RATIO

This is when the ratio of gasoline
to oil is less.
e.g.:
20:1
30:1
40:1
etc.
e.g.:
20:1
is richer than
24:1
CONS
Increased carbonizing of engine:
Deposits on exhaust port,
piston and head
Excessive carbon build-up can cause
scoring of piston and cylinder
Excessive carbon build-up can
decrease heat dissipation
Need to de-carbonize more often
Spark plug fouling
LEAN MIXTURE RATIO

This is when the ratio of gasoline
to oil is higher.
Fuel does not burn efficiently:

Reduced performance
More pollution
Blockage of spark arrestor
PROS
Good lubrication
Able to operate at higher ambient temperatures
e.g.:
30:1
is leaner than
CONS
PROS
Decreased lubrication:
Reduced carbonizing
Possibility of piston / cylinder

scoring / seizure
Engine operates hotter
More susceptible to damage
when operating at higher ambient
temperatures
24:1
Fuel burns more efficiently:

Clean burn
Less pollution
Better performance
Better fuel combustion
11/2012
ENGINE
OPERATING
THE IMPORTANCE OF FUEL / MIXTURE RATIO, AIR / FUEL

RATIO AND OIL CONSIDERATIONS
PROPER MIXTURE
Wildfire recommends a mixture
ratio of 24:1 using Castrol 2-Stroke
Super Stroke (or similar) for the MK-3.
Good lubrication
Good performance
Cost effective
Reduced chance of scoring of piston / cylinder
Possible to operate at high engine speed
& temperature without damage
24:1
Reduced carbonizing
Pump end does not get dirty
from excessive oil
Engine operates at normal temperatures
THE IMPORTANCE OF PROPER AIR FUEL A/F RATIO

When adjusting the idle and high speed
carburetor adjustment it is important not
to adjust the carburetor too lean or too
rich otherwise engine damage can result.
The ratio of the amount of AIR to the amount

of FUEL being introduced into the combustion
chamber
LEAN A/F RATIO
RICH A/F RATIO
The ratio of air to fuel is higher

(higher air content in the air / fuel ratio)
The ratio of air to fuel is lower

(lower air content in the air / fuel ratio)
Less fuel (gasoline + oil) in the air / fuel

mixture less lubrication
More fuel (gasoline + oil)more lubrication
Less lubricationpossible piston /

cylinder scoring
Carbonizes easier / quicker
Not good to operate in high ambient

temperatures
Engine runs cooler

Performance decreased
Not as responsive
Runs hotter
More smoking
Burns cleaner
Combustion not as efficient
Good performance (if too lean then

performance drops off)
11/2012
A/F RATIO
ENGINE
OPERATING
A/F ADJUSTMENT: ALTITUDE VARIATIONS

It is very important to adjust carburetor when moved from a HIGHER ALTITUDE to a LOWER ALTITUDE
and vice versa.
Example:
At higher altitudes there is less oxygen therefore you need to adjust the carburetor to maintain
a proper A/F RATIO (we need to decrease the amount of fuel in the A/F ratiolean out). If the
carburetors (adjusted lean for high altitude) are not re-adjusted when the engine is taken down to
sea level conditions (lower altitude) the engine will be operating with a much leaner A/ F RATIO (more
air at lower altitudes) and possibly cause engine damage.
A/F ADJUSTMENTS: AIR FILTERS
The condition of the air filter can cause the A/F ratio to vary. A dirty air filter restricts the amount of
air that can enter the carburetor resulting in a richer A/F ratio. Some operators make the mistake of
adjusting the A/F ratio as the air filters gets dirtier by leaning out the carburetor instead of
cleaning/changing the air filter. As soon as the air filter is either changed or cleaned (A/F ratio not
re-adjusted) more air will be able to enter the carburetor resulting in a much leaner A/F mixture which
can result in possible engine damage.
A/F ADJUSTMENTS: DIFFERENT FUEL MIXTURE RATIOS
The A/F ratio and the fuel mixture ratio are closely linked. The following cases will better describe
how they are related.
LEAN FUEL MIXTURE RATIO

LEAN A/F RATIO
RICH A/F RATIO
The A/F ratio is extremely critical when using a

lean Fuel Mixture Ratio. If the carburetor is
adjusted too lean, then there will be less fuel
(gasoline + oil) which in turn results in decreased
lubrication. At this point the engine will be
operating hotter and if the ambient temperatures
are higher and if the engine is operating at a
higher engine speed, the possibility of engine
damage resulting is quite high. If the A/F ratio is
too lean, in addition to higher temperatures, a
loss of power will also be observed.
If the A/F ratio on the carburetor is adjusted rich,

the engine will begin to smoke due to improper /
incomplete combustion. A noticeable lack of
power will be observed.
RICH FUEL MIXTURE RATIO

LEAN A/F RATIO
RICH A/F RATIO
If the carburetor is adjusted with a lean A/F ratio,

there will be less fuel (gasoline + oil) which in
turn will result in a decreased lubrication. With a
richer fuel mixture ratio, a lean A/F ratio setting
is not as critical as with a Lean Fuel Mixture ratio.
There may still be enough lubrication (depending
on the fuel mixture ratio and the A/F ratio) to
prevent engine damage but caution must be
taken to properly adjust the carburetors.
When dealing with a rich fuel mixture it is critical

not to operate the engine with a rich A/F ratio. If
this happens the engine will smoke and carbon
deposits will form. It will be necessary to
de-carbonize the carbon deposited areas. If the
deposit formations are not removed, the engine can
start to heat up and possible scoring could result
due to bits of the carbon breaking off and getting
lodged in between the cylinder and piston.
A noticeable power loss will be experienced.
11/2012
10
ENGINE
OPERATING
11
OIL CONSIDERATIONS
There are different types of 2 cycle oils that
can be used:
Mineral
Castor Bean Oil
Synthetic
Semi-synthetic
MINERAL
Cost effective, not too expensive
Readily available
SYNTHETIC
Mixes very well with oil since composition
of Synthetic oil is close to that of gasoline
Produces low ash therefore reduced deposit
formation
Leaves a thin lubricating film on cylinder
wall
Thin lubricating film on cylinder wall has
difficulty providing adequate lubrication
when dealing with a hot air cooled engine
Leaves a nice lubricating film on the cylinder

walls and does not run off
Much more expensive
Good lubricity
Possible varnishing on cylinder walls
Lubricating film on cylinder wall does not

run off when in storage over periods of time
Some manufacturers may require a break-in

period or greening of the engine
Higher ash
Cannot readily interchange from synthetic

to non-synthetic and back (dependant on
manufacturers recommendations)
Can leave deposit formation on:

- exhaust port
- piston rings
- piston crown
CASTOR BEAN OIL

Very gummy dirty oil
Not readily available
The thin lubricating film on cylinder walls

can run off during longer storage periods
leaving the surface unprotected; corrosion
and dry starts leading to damage
Dyno test have not shown an increase in
performance using synthetic oil
Resists seizure under extreme conditions

Very high ash much higher deposit
formation
Requires frequent disassembly for deposit
removal
Used in racing where crucial lubrication
is required and frequent disassembly,
cleaning and re-assembly is performed
SEMI-SYNTHETIC
A compromise between synthetic and
mineral based oils
Higher cost
Not always readily available
Has a lesser degree of run off
CONCLUSION
11/2012
Wildfire suggests using Castrol 2 Stroke Super Stroke or similar

mixing oil due to the positive results when used in the MK-3 at a
24:1 mixture ratio. Tests have been conducted using synthetic and
semi-synthetic oils but found varying results with variations in
fuel quality and oil quality with some results leading to piston
damage or piston ring sticking.
12
ENGINE
OPERATING
FLOODING
Flooding refers to an accumulation of excess fuel in cylinder, mainly due to excessive use of choke.
When the engine is in a flooded condition, an over-rich fuel-air mixture is induced into the cylinder.
This mixture does not ignite readily and usually fouls the spark plug.
In cold operation, it is
good practice to put a
small quantity of
aluminum compatible
antifreeze into the pump
end through the priming
cap immediately after
use to prevent damage
from freezing.
COLD WEATHER
Recommended Procedure for Cold Weather or Prolonged Storage
The following procedure is recommended to ensure proper protection of the engine if the engine is
to be left idle for prolonged periods between uses or if there is a possibility that the engine may be
stored in an unheated area where freezing temperatures may occur.
1. With pump unit running at low RPM, remove the quick-connect fuel line from the quick-connect
fitting on the engine.
2. Allow engine to run until all fuel has left the carburetor and the engine stops.
3. Remove spark plug.
4. Rotate crankshaft until piston is at top dead centre.
5. Pour 30 ml (1 oz) of oil into spark plug opening (use same oil grade used in fuel mixture).
6. Rotate crankshaft 2 or 3 times to ensure that cylinder walls are well coated with oil, then bring
piston to top dead centre.
7. Reinstall spark plug.
8. Keep the pump unit in dry storage above freezing temperature.
11/2012
COLD OPERATION
CLEARING A FLOODED ENGINE

Remove fuel supply line from engine or close fuel supply valve (if equipped). Remove spark plug. With
both choke and throttle in fully open position, pull starter rope several times until excess fuel is
exhausted. Before reinstalling spark plug, clean and dry electrode and insulator tip.
13
TROUBLESHOOTING CHART
ENGINE DOES NOT START OR STARTS
MOMENTARILY THEN STOPS
Possible cause
Fuel supply tank empty
Fuel supply valve closed
Air vent on fuel tank closed
Defective fuel supply hose
Dirty fuel strainer screen
Leak in fuel supply system
Carburetor mountings loose
Water or dirt in fuel system
Engine flooded
Too much oil in fuel mixture
Spark plug fouled or defective
No spark
Remedy
Refill fuel tank
Open supply valve
Open air vent or unscrew cap
Replace
Clean or replace
Tighten or replace fittings
Tighten mountings
Drain; flush thoroughly
See Flooding
See Operating Instructions
Clean or replace
See Electronic Ignition
Module Settings
ENGINE RUNS IRREGULARLY OR MISSES

Possible cause
Defective fuel supply hose
Dirty fuel strainer screen
Leak in fuel supply system
Water or dirt in fuel system
Wrong gasoline in fuel mixture
Air filter dirty
Idle mixture screw misadjusted
Wrong type of spark plug
Improper timing
Remedy
Replace
Clean and replace
Tighten or replace fittings
Tighten mountings
Drain; flush thoroughly
See Engine Lubrication and Fuel
Clean or replace
See Carburetor Adjustment
Clean or replace
Use recommended plug
Refer to Electronic Ignition Unit
ENGINE BACKFIRES
Possible cause
Defective carburetor
Improper timing
Remedy
Clean or replace
Replace
ENGINE DOES NOT IDLE PROPERLY

Possible cause
Idle mixture screw misadjusted
Main adjustment screw
misadjusted
Improper timing
Remedy
Tighten mountings
Clean or replace
Use plug recommended
ENGINE DOES NOT DEVELOP NORMAL

POWER AND/OR OVERHEATS
Possible cause
Wrong gasoline in fuel mixture
Wrong oil in fuel mixture
Not enough oil in fuel mixture
Air filter dirty
Cooling system dirty
Muffler blocked or dirty
misadjusted
Improper timing
Remedy
Tighten mountings
Replace
Clean or replace
Use plug recommended
Clean cooling system
Replace
ENGINE SOUNDS LIKE A FOUR STROKE

Possible cause
Engine not warmed up properly
misadjusted
Air filter dirty
Improper timing
Remedy
Allow longer warm up period
Clean or replace
11/2012
Refer also to the Servicing Carburetor section for additional

Trouble Data and Service Information.
14
ENGINE
OPERATING
ELECTRONIC IGNITION
In May of 2004, Wildfire announced that the standard MARK-3 units would feature an
electronic ignition system as opposed to the previous pointed ignition system.
The upgrade to the electronic ignition system has eliminated the need for regular maintenance
associated with breaker points. The electronic ignition system uses a magnetic pickup located on
the flywheel which, when passing over a certain point on the stator, will induce a high
voltage that causes the spark plug to fire at the proper moment.
The electronic ignition module is equipped with spark advance, thus allowing for a cleaner burn
at higher RPM levels. The engine will run smoother and will be more responsive. Note that when
the engine is started cold, it will run "rough" (as if the timing is off) for about 15-30
seconds, after which the engine will run smoothly.
In order to convert a MARK-3 from breaker points to the upgraded electronic ignition system, a
retrofit kit was created (B-7595). This manual provides step-by-step instructions on how to perform
the conversion.
A more efficient and

maintenance free electronic
ignition system.
The electronic ignition allows

for a smoother and more
responsive engine run.
The breakdown of the electronic ignition is shown below. The electronic module is placed in an
aluminium box located on the frame below the carburetor shroud.
Ref. #
Part#
Description
Qty
--
B-7595
MARK-3 Conversion Kit (Point to CDI)
1
2
3
4
5
6
7
8
9
10
11
12
13
-----
R-271
A-7589
D-2902-9
FAST-18
QHOSNEO5/16BL*
QWICO18GABLK*
PART-37
FAST-20
FAST-510
R-150
A-6510
B-5562-18
C-7010-12C
MAN-B-7595
PART-260*
QHEATSH1/2D*
QHEATSH1/4D*
Electronic ignition conversion kit

Mounting block, electronic ignition
Grommet
Bolt, hex, steel, plated
Hose, 5/16" ID x 7/16" OD, neoprene
Wire, 18 ga., black
Female disconnect terminal, insulated
Bolt, hex steel plated
Flat washer, steel plated
Lock nut, steel, plated
Decal for electronic ignition box
Plastic coated clamp
Female bullet terminal, insulated
Manual, MARK-3 conv. kit, point to CDI
Split loom, 3/8"
Heat shrink tubing, 1/2"
Heat shrink tubing, 1/4"
1
1
2
2
0.5
0.83
1
2
2
5
1
1
1
1
0.92
0.17
0.17
* Please note that these items are not sold as spare parts.
NOTE
1
3
5
8
13
12
11
1
9
10
11/2012
For step-by-step instructions

to convert from a pointed
engine to CDI please refer
to the Appendix.
PUMP UNIT
PUMP OPERATION AND LUBRICATION

Ref. #
_
1
2
3
4
5
6
7
8
9
Part #
Description
212-170P
A-4460
A-4452
C-4462-5
A-4455
B-4461
B-4457
A-4454
A-4456
A-4453
Pump clamp
Lever sub-assembly
Side link for lever
Cotter pin
Clevis pin, lever side
Clamp, top half
Clamp, bottom half
Clevis pin, eye bolt side
Knob for tension adjustment
Eye bolt
Qty
1
1
3
2
1
1
1
1
1
6
5
11/2012
15
16
PUMP UNIT
PUMP LUBRICATION
Pumps requiring greasing must be lubricated every 8 hours of operation and after each use.
IMPORTANT
Pump ends (12-16S) with
the sealed bearing (12-48S)
do not require greasing.
Use a clean grease gun filled with fresh grease. Remove dirt from grease fitting before applying grease
gun. Grease should be pumped slowly into grease zerk while rotating the pump shaft. Continue
pumping until fresh grease appears around bearing ring. Wipe off excess grease.
Do not use graphite grease or a pressurized grease gun.
TO REMOVE PUMP FROM ENGINE
1. Lift pump clamp lever.
2. Release tension adjusting knob at bottom of clamp.
3. Remove clamp by tapping bottom end of each half clamp.
4. Remove pump from engine.
TO ATTACH PUMP TO ENGINE
Apply FINGER PRESSURE

ONLY to close pump clamp
lever. Excessive pressure
will damage or break
clamp link.
1. Place flexible buffer coupling on engine coupling pins.

2. Align flexible buffer coupling holes to pump end coupling pins and install.
3. Attach pump clamp. Carefully align clamp positioning pins with flange stub.
4. Adjust tension knob located at bottom of clamp to obtain a light pressure on
clamp ring.
TO DRAIN PUMP
It is recommended that the pump be drained after usage. This is a MUST during cold weather, to
prevent damage to pump, due to freezing.
1. Remove discharge hose, suction hose, and priming cap.
2. Drain pump by tilting pump body several times.
3. Stand pump on suction nozzle end for several minutes to complete drainage.
4. Replace discharge, suction, and priming caps.
TESTING PROCEDURE
The A-2388 pump test kit is designed to verify the condition of a pump unit by completing a
performance test. This is achieved through running the unit at three key nozzle bore sizes: (6 mm),
(9.5 mm), and at (12.7 mm). Verify that the pressure output at full throttle is at or above the
below-listed minimal pressure ranges by reading the pressure gauge at each nozzle setting. The pump
unit should be sent to a service center if it fails any one of the testing points. (See next page for kit
breakdown).
Nozzle
Size
Minimal
Pressure
Range
*1/2"
12.7 mm
100-105 psi
689-724 kPa
7/16"
11 mm
125-130 psi
862-896 kPa
*3/8"
9.5 mm
165-170 psi
1138-1172 kPa
5/16"
8 mm
210-215 psi
1448-1482 kPa
*1/4"
6 mm
255-260 psi
1758-1793 kPa
1/8"
3 mm
315-320 psi
2172-2206 kPa
*Test kit includes (6 mm), (9.5 mm), and at (12.7 mm) test points
11/2012
IMPORTANT
PUMP TEST KIT
Ref. #
-1
2
Part #
A-2388
A-2392
F5095E
3
4
5
6
7
A-2389
A-2391
A-2391B
A-2390A
A-2390
A-2395
C-1933
Description
Pump test kit (incl. all the parts listed below)
Pressure gauge 0-400 psi (0-2800 kPa)
Hose SPEC 187-1 1/2" x 10' with aluminum coupling
NPSH M/F F5095E00F10RAAFSS
Pump test kit box
Rubber hose assembly (incl. a set of 2 adaptors A-2391B)
Adaptor Female NPT-Swivel Female 2
Shut-off valve
Pressure gauge adaptor 1 1/2" (38 mm) female NPSH to
1 1/2" (38 mm) male NPSH
Brass calibrated nozzle tip set:
includes 1/4 (6 mm), 3/8 (9.5 mm)
Calibrated nozzle, 1/2" (12.7 mm)
17
Qty
1
1
1
1
2
1
1
1
1
PUMP ADJUSTMENTS
Overspeeding may occur if:
1. Pump not primed properly.
IMPORTANT
Carburetor should be
properly adjusted before
starting performance test. See
"Carburetor Troubleshooting
Chart". In addition, the pump
unit should be set up as close
as possible to water source.
Suction hose and/or pump body not completely filled with water.
A bend in the suction hose, located higher than the pump suction inlet, causing an air lock.
(The suction hose between the pump and water supply must have a downward slope.)
2. Loose suction hose coupling or priming cap.
3. Footvalve strainer clogged or too close to surface of water.
4. Pump loses prime.
Due to lack of water, air lock may form in the suction hose when pump unit works against a
high delivery head. If this happens, disconnect the discharge hose from the pump then reprime
pump in the normal manner.
11/2012
Pump runs out of water, either because of lack of sufficient water supply or by attempting to
pump water from a shallow water source.
18
PUMP UNIT
The footvalve must remain at least 30 cm (1 foot) under the water surface while pump is operating.
All suction couplings, including footvalve, must be wrench tightened. Proper fitting gaskets must be
used in all coupled joints. Worn or dried out gaskets should be replaced with new gaskets.
DIGITAL OVERSPEED SWITCH (DOS)

NOTE
For information on previous
mechanical cut-out switch
system (B-6288) please
refer to the Appendix
section.
DOS
OFF button
One common failure associated with fire pumps is in overspeed condition. This occurs when the pump
end experiences a loss of prime. Not enough water in the pump end severely unloads the engine and
causes it to race to speeds outside safe operating parameters.
Wildfire previously used a mechanical cut-out switch to deal with the problem of overspeed.
The Digital Overspeed Switch (DOS) continuously monitors the engines speed through the use of a
microcontroller which, once overspeed is detected, re-validates that the condition exists then
immediately shuts down the pump. Adjustment of a tension spring is no longer required. An ON/OFF
switch is also no longer required. This also reduces the amount of wiring and spare parts necessary
for each unit. Can be installed on any MARK-3 equipped with electronic ignition module.
POWER
The DOS unit derives power from the engine and therefore does not require the use of batteries. The
unit powers up once the engine is operating.
INTEGRATED OFF SWITCH
With the DOS installed the ON switch is no longer required. The MARK-3 unit is, hence, always ready
to start. However, the DOS incorporates an OFF switch which the operator can activate when needed.
INSTALLATION
The DOS uses one single wire making installation simple. The DOS easily installs on the side of the
fan cowl above the carburetor shroud.
For end users with the current MARK-3 CDI units with (B-6288) mechanical cut-out switch the
necessary kit required in order to convert to DOS is B-6289. An instruction sheet for installation
purposes is provided with every kit. Please refer to Appendix (DOS Instruction Sheet).
NOTE
The DOS feature is available exclusively for MARK-3 fire pumps with CDI units that is, units
with an electronic ignition module (any MARK-3 purchased after November 2003). The DOS
became a standard feature for all MARK-3 units back in June 2009 with the
exception of the MARK-3 GSA version.
Wildfire strongly recommends using a robust type spark plug connector

OEM model R-650 (refer to image) when operating the MARK-3 with
the DOS. This OEM spark plug connector (R-650) has been thoroughly
tested and approved for usage on our MARK-3 as a result of its signal
shielding capability which ensures the proper operation of the DOS.
Usage of another type of spark plug cap may lead to a potential DOS
malfunction and will inherently limit any applicable warranties.
11/2012
CDI
Electronic Ignition Module
REGULAR
MAINTENANCE
MAINTENANCE CHECK LIST

Regular maintenance is a schedule of continous
systematic maintenance, designed to prevent
frequent or major breakdowns before they
occur.
Maintenance on a fire pump unit should
not be done on the fire line. Always, check
your pump unit immediately after use.
1. Clean unit thoroughly.
2. Clean air filter.
3. Clean fan housing and air intake screen.
4. Make sure cooling passages and cylinder
fins are clean.
5. Make sure spark plug is cleaned and has
proper gap setting.
6. Check stop switch for proper operation.
7. Check throttle and choke control for proper
operation.
8. Make sure carburetor fuel strainer screen
is clean.
19
9. Check fuel line and fittings for signs

of wear, etc.
10. Check and grease pump end
(as per instructions in previous section).
11. Check starter cable and mechanisms and
replace if it shows signs of wear.
12. Check condition of buffer coupling.
13. Operate pump unit and check general
performance. Adjust carburetor if necessary
( (See Carburetor Adjustment page 26).
14. Check carburetor adjustments.
15. Note any performance irregularities or any
abnormal mechanical sounds.
16. Make sure pump seal is not leaking.
17. Make sure that all necessary tools, spares
and accessories are with pump unit. It is
strongly suggested to always have an extra
spark plug on hand.
18. Make sure electronic ignition module is
free of debris. Verify condition of wiring
and connections.
Ref. #
Part #
Description
Qty
_
1
2
3
4
5
6
7
8
9
10
11
12
13
14
R-900
PART-117*
271-923
R-911M
R-906M
R-910
R-902
R-904
A-3023
R-901
R-903
R-908
R-905
271-488
271-928
Maintenance tool kit (incl. all parts listed below)

Grease gun
Wrench - adjustable 8" (203 mm)
Wrench - box & open end 1/2" (13 mm)
Wrench - box & open end 3/8" (10 mm)
Wrench - open end 1/2"-9/16" (13-14 mm)
Screwdriver 2" (51 mm)
Wrench - spark plug
Carburetor adjusting tool
Screwdriver, 4" (102 mm) sq. handle
Feeler gauge - spark plug & breaker point
Wrench - open end 5 & 8 mm (ignition)
Handle - rod
Bag - tool roll (not shown)
6 mm T-handle Hex 10.5" LG
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
* Not required for pump ends with maintenance-free sealed bearing.

3
4
5
2
10
14
1
8
7
12
11/2012
11
20
REGULAR
MAINTENANCE
SERVICING SPARK PLUG

Operating with a defective or incorrect spark plug will affect the engine's performance and can cause
hard starting, fouling, missing, overheating, pre ignition and/or lack of power. To service and inspect
the spark plug, the following steps must be performed.
1. Remove spark plug cover.
2. Disconnect spark plug cable and remove spark plug.
Refer also to section on

"Servicing Carburetor"
for additional "Trouble
Data" and service
information.
3. Clean spark plug and inspect carefully. If tip of insulator core is rough, cracked, broken or blistered,
or if electrodes are burned away to the extent that they are too thin and cannot be satisfactorily
adjusted to recommended gap. 0.016" -0.020" (0.41-0.51mm), replace with new plug.
Note: Use R-629 spark plug.
Use only spark plug type specified by engine manufacturer.
4. Reinstall spark plug. Start threads one or two turns with fingers to avoid danger of cross threading.
Tighten spark plug to recommended torque of 25 Nm (18 ft-lbs or 215 inch-lbs).
5. Connect spark plug cable.
6. Install spark plug cover; tighten screws securely.
Caution: Ceramic insulation of spark plug is easily damaged by shock stresses or bending
stresses as may be imposed by dropping, striking with hard objects or overtightening. Therefore,
if spark plug has been subjected to such accidental abuse, it should be carefully inspected and tested
before further use.
UPGRADED SPARK PLUG CAP
For years the MARK-3 was using a rubber spark plug connector R-650. The rubber
connector was known to crack where the wire goes into the connector and where the rubber
connector goes onto the spark plug.
The rubber connector has since been replaced by a robust type of connector used on high
performance recreational vehicles. The connector has the added benefit of being able to shield
against noise signals.
The part number remains R-650.
A robust type of connector has replaced the old

spark plug rubber cap.
11/2012
IMPORTANT
REGULAR
MAINTENANCE
21

Procedure:
Remove old flywheel and armature plate.
Fit the new armature plate so that the long holes are aligned
counter-clockwise, then tighten the 3 screws.
2
1
, then turn it approx. 1 mm
Turn crankshaft until the piston is 3.75 mm before top dead centre, measuring through the spark
plug hole with a dial gauge. For the final dynamic ignition timing check make an ink mark on the
coupling buffer 12-17 as well as on the flange pump mounting R-136.
Fit electronic box.
Start engine and check ignition timing with a stroboscopic lamp. The 2 marks previously
made must correspond at 3000 4000 r.p.m.
If the 2 marks do not correspond, remove flywheel and loosen the 3 screws of the armature
plate, turn armature plate slightly in the direction needed. Repeat the procedure until the marks
correspond.
Seal rubber grommet with Silastic.
4
3
TO SPARK PLUG
TO GROUND (RED)
TO COIL (GREEN)
5
TO STOP & CUT-OUT
SWITCHES (BLACK)
OR TO DOS
11/2012
MUST BE INSERTED BEFORE

INSTALLING ELECTRONIC BOX
REGULAR
MAINTENANCE
ELECTRONIC IGNITION MODULE SETTINGS

Table
Resistance value Check
Resistance value Check
System
116 mm Flywheel magneto
CDI unit with H.V. coil
Part number
492.19.6009
432.39.9510
Green wire
225 255
Ground (stator)
225 255
-
FLYWHEEL MAGNETO
+/Green wire
Ground (stator)
CDI UNIT WITH INTEGRATED IGNITION COIL

+/testing pin
STOP
VERDE (G)
Ground
H.V. output.
STOP
0.1
50 M
50 M
VERDE
(G)
0.1
50 M
50 M
Ground
(red wire)
50 M
50 M
4.7 5.5 K
H.V. output
(AT)
50 M
50 M
4.7 5.5 K
-
NOTES
Testing Temperature: 25 C.
Values (in ohm) detected by Tester Digital BECKMAN RMS 3030.
The above said values are not always a guarantee of perfect efficiency of the part.
11/2012
22
REGULAR
MAINTENANCE
23
FOR UNITS EQUIPPED WITH A DECOMPRESSION SWITCH
DECOMPRESSION SWITCH R-233DS

The MARK-3 model MK3-DTQS features a decompression switch that significantly facilitates starting
the pump.
To convert an existing MARK-3, simply replace the cylinder head with a R-233DS (cylinder head
with decompression switch assembly)
KEY CHARACTERISTICS
Decompression switch makes easy pulling / starting of recoil starter.
Engine fires up easier
No kick back
R-233DS
Easily engaged, simply push decompression switch in

Automatically disengages / closes when engine starts
PARTS BREAKDOWN
Decompression Switch: A-7627
Copper Washer: A-7628
Cylinder Head: R-233 (machined head not sold separately)
Head Gasket: R-238 (not shown)
A-7627
A-7628
INSTALLATION NOTES
Torque value for decompression switch: 190-210 in-lbs (21-24 Nm).
Note: The decompression switch and cylinder head must be cool prior to installation.
The threads on the decompression switch and on the cylinder head must also be clean.
Install cylinder head with decompression switch oriented towards pump end.
R-233
11/2012
Exploded view R-233DS
24
REGULAR
MAINTENANCE
10
31
19
9
8
11
32
35
36
37
38
39
33
12
33
40
15
14
13
34
6
5
41
18
17
19
20
21
22
23
24
25
26
27
28
29
30
11/2012
16
42
25
CARBURETOR DESCRIPTION
Ref. # Part #
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
Repair parts kit

Carburetor
Body
Carburetor gasket, isolating flange
Mach. screw with lock washer
Throttle shutter
Throttle shaft and lever
Throttle shaft return spring
Throttle shaft clip
Lock washer
Machine screw
Bolt
Throttle link lever assembly
Nut
Choke shutter
Choke friction pin
Choke friction spring
Choke shaft and lever
Body channel welch plug
Nozzle check valve
Inlet control lever
Diaphragm gasket
Diaphragm
Diaphragm cover
Fuel pump gasket
Fuel pump diaphragm
Fuel pump body
Fuel strainer screen
Fuel strainer cover gasket
Fuel strainer cover
Machined screw
Mach. screw with lock washer
Inlet control lever fulcrum pin
Inlet tension spring
Inlet needle and seat
Inlet control lever pin lock screw
Inlet seat gasket
Idle speed screw O-ring
Flat washer, brass
Idle / High speed mixture screw spring
Idle mixture screw
High speed mixture screw with pin
Idle speed screw spring
Idle speed screw
R-1050
R-1115
R-1045
R-1113
R-1041*
R-1040*
R-1035
R-1039
R-1036
R-1037
R-1038*
R-1111
R-1101*
R-1110*
R-1005
R-1002*
R-1003
R-1004
R-1001
R-1034
R-1025N
R-1008
R-1009
R-1010
R-1011
R-1012
R-1013
R-1015
R-1016
R-1017
R-1018
R-1014*
R-1025NA
R-1029
R-1046N
R-1025NB*
R-1047
R-1022
R-1021
R-1020
R-1019
R-1030
R-1024*
R-1023*
11/2012
*Please note that these parts are not sold as spare parts.
Qty
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
6
1
1
1
1
1
2
2
2
1
1
1
1
The carburetor can be cleaned with a minimum of tools. Before

disassembling carburetor it is imperative to flush it clean of
dirt by using proper carburetor cleaner.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Remove strainer cover retaining screw and plastic cover.

Remove strainer cover gasket and strainer screen.
Remove screws and fuel pump body.
Remove fuel pump diaphragm and gasket.
Remove main diaphragm cover plate.
Remove main diaphragm and main diaphragm gasket.
Remove inlet control lever fulcrum pin, lever and tension
spring.
Remove inlet needle.
With a thin wall 8 mm (5/16") hex socket carefully remove
the inlet seat. Remove inlet seat gasket. When reinstalling
seat, tighten only to 3 or 4 Nm (25-35 inch-lbs).
Remove idle and high speed mixture screws.
When reinstalling O-ring type adjusting screws, lubricate
with SAE-30 oil to prevent seizing. Packing spring type
adjustments do not require lubrication.
The ball check type main nozzle can be removed by
tapping it out of the body casting into the venturi with a
small punch. A replacement ball check nozzle should be
pressed into the casting. The brass cage should be pressed
flush with the metering chamber casting.
Before reassembling the carburetor (in reverse order as

outlined above) wash all component parts in carburetor
cleaner and blow off with compressed air. The channels in the
metering body should be cleaned by blowing through the idle
and main adjusting orifices. All fuel passages in the three
castings should be cleaned with compressed air.
Do not clean orifices or passages with wires or drills as
this might damage and cause incorrect operation of the
carburetor.
When reassembling the inlet control lever and spring, make
sure that the spring rests in the well of the metering body and
locates on the dimple of the inlet control lever.
Do not stretch spring. Inlet control lever is properly set when
flush with floor of diaphragm chamber.
Be certain main diaphragm, gasket and cover casting are
carefully fitted over the three small pins cast in rim at bottom
of metering body. Also the fuel pump gasket, diaphragm and
fuel pump body are placed over similar pins at bottom rim of
main diaphragm cover casting. Evenly tighten fuel pump body
retaining screws to insure complete seal of casting separations
at both diaphragms.
Frequent cleaning or replacement of the fuel strainer screen
will aid satisfactory operation of the carburetor.
REGULAR
MAINTENANCE
CARBURETOR ADJUSTMENT
The carburetor is provided with three adjustments, namely high speed (main) adjustment; low speed
(idle) adjustment; and idle speed regulating screw.
1. Before starting pump unit, close both main and idle adjustment screws, by turning clockwise,
until needle just touches seat.
Note: Turn adjustment screws carefully and gently. Do not force needle into seat, otherwise, both
needle and seat may be permanently damaged.
2. Open main adjustment screw 1 turn, by turning counterclockwise.
3. Open idle adjustment screw 1 turn, by turning counterclockwise.
4. Turn idle speed regulating screw until throttle shutter is slightly open.
5. Start unit. Open choke slowly, and allow engine to warm up thoroughly, gradually
increasing speed to full throttle setting while running with 6 mm (1/4") diameter nozzle tip
connected to a 3 m (10') discharge hose.
6. When engine is thoroughly warmed up, close throttle, then adjust idle adjustment screw and idle
speed regulating screw, until engine idles smoothly between 2000-2200 RPM.
7. Increase speed gradually to full throttle setting, then turn main adjustment screw until engine
gives maximum RPM and pump delivers maximum pressure. Then, turn main adjustment screw
1/4 turn maximum counterclockwise. This setting will give correct mixture ratio to assure proper
engine lubrication.
Do not leave main adjustment screw set too lean, otherwise serious engine damage may occur due
to lack of sufficient lubrication.
Note: It will be necessary to readjust the carburator when taking the pump from one altitude and
placing in a different altitude. Repeat steps 1 to 7.
11/2012
26
27
REGULAR MAINTENANCE
CARBURETOR TROUBLESHOOTING CHART
CARBURETOR FLOODING
Possible cause
Dirt or foreign particles preventing inlet needle from seating.
Diaphragm lever spring not seated on lever dimple.
Diaphragm improperly installed in carburetor.
Improper use of choke
ENGINE WILL NOT ACCELERATE
Possible cause
Idle adjusting screw set too lean.
Incorrect setting on diaphragm lever.
Diaphragm cover plate loose.
Diaphragm gasket leaking.
Main fuel orifice plugged.
ENGINE WILL NOT IDLE

Possible cause
Incorrect idle adjustment.
Idle discharge ports or channels clogged.
Diaphragm lever set incorrectly.
Throttle shutter cocked in the throttle bore causing fast idle.
Dirty nozzle check valve.
Welch plug covering the idle discharge ports does not seal.
This causes the engine to idle with idle adjustment shut off.
ENGINE RUNS OUT LEAN
Possible cause
Tank vent not working properly.
Leak in fuel system from tank to pump.
Ruptured fuel pump diaphragm.
Main fuel orifice plugged.
Remedy
Remove, clean and replace.
Remove lever and reinstall.
Replace diaphragm or correct installation.
Proper use of choke at start-up
Remedy
Enrich idle adjustment.
Reset.
Tighten.
Replace.
Remove diaphragm cover, diaphragm, diaphragm lever and main
adjusting screw. Clean out orifice by blowing through main
adjustment threaded hole.
Remedy
Reset to best idle.
Blow out with compressed air, or if compressed air is not available,
clean and flush with gasoline.
Reset diaphragm lever so it is flush with the floor of the diaphragm
chamber.
Reset.
Clean and/or replace.
Replace welch plug.
Remedy
Clean and/or replace.
Tighten or replace fittings or lines.
Replace.
Clean.
11/2012
CARBURETOR RUNS RICH WITH MAIN ADJUSTMENT SHUT OFF

Possible cause
Remedy
The nozzle channel plug, or nozzle check valve cage, is not sealing. Install new plug or new cage.
28
AIR FILTER
Ref # Part #
Description
R-793
Mach. screw, stainless steel,

nylon insert
R-791
Lock washer, steel, plated
3
4
5
6
R-1044
R-794
R-955
R-790
1
1
1
1
7
8
9
10
11
12
13
14
15
12-79
B-4036-12
R-799
R-774
R-1102
B-4024
R-1107
A-4028
A-4027
Lock plate
Cover for air filter
Air filter element - foam & screen
Carburetor shroud
(includes decal A-4030)
Mach. screw, hex socket cap, steel
Bracket
Mach. screw, steel, plated
Link for throttle
Quadrant for throttle lever
Throttle lever sub-assembly
Spring, stainless steel
Index pin
12
Qty
13
14 15
11
4
2
1
2
1
1
1
1
1
8 9
10
CYLINDER ASSEMBLY
6
Description
Qty
R-150
2
3
4
5
6
7
8
9
R-149
R-402
R-1113
R-238
R-233
R-235
R-270
R-257*
2
2
1
1
1
1
1
1
10
11
12
13
R-237
R-117
R-119
R-120

Stud, steel
Carburetor gasket, isolating flange
Cylinder head gasket
Cylinder head
Cylinder flange gasket
Cast iron cylinder sleeve
Cylinder
(incl. cast iron cylinder sleeve R-270)
Muffler gasket
Stud, steel
Nut, hex, plated
1
2
2
2
2
3
4
10
11 12 13
11/2012
Ref. # Part#
REGULAR
MAINTENANCE
Efficient engine cooling is
accomplished by a fan attached
to the flywheel. This fan pulls air
through the fan housing screen,
then forces the air around the
cylinder and through the spaces
between the cylinder and
cylinder head fins.
In time the cooling air passages
will become partially clogged
and the fins will become coated
with dirt and thereby reducing
the cooling efficiency.
Therefore, whenever this
condition occurs, remove fan
housing then use compressed
air or a stiff bristle brush and
appropriate cleaning solution to
remove all dirt deposits from fins
and from inside the fan housing.
COOLING SYSTEM
Ref #
Part #
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
R-414
R-119
R-413
R-408
12-38
R-409
R-411P
R-115
R-402
R-418
R-150
TY-1811
R-151

Cover for spark plug
Lock washer, stainless steel
Ignition cable clamp, steel, plated
Fan cowl with studs, painted (incl. R-115 & R-402)
Stud, steel
Stud, steel
Fan shield, steel, painted
Flat washer, steel, plated
11
12
Qty
11
2
2
1
1
3
1
1
3
1
1
2
2
1
12
11/2012
29
13
10
30
REGULAR
MAINTENANCE
REWIND STARTER
Ref #
Part #
Description
Qty
--
R-529
Rewind Starter Assembly
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
R-518
R-517
R-516
R-526
R-528
R-510
R-504
R-506
R-531
R-530
12-38
R-522
R-524
R-523
R-532
R-509
R-505
R-502
R-533
R-544
R-501
Circlip, steel
Friction spring, steel
Friction washer, steel
Pawl assembly
Flat "D" washer, steel
Sheave for starter rope
Rewind spring
Rewind spring retainer
Starter housing
Rewind starter cover
Plug
Lock pin
Starter rope
Starter rope guide
Rubber buffer
Rewind starter handle
21
1
1
1
1
1
1
1
1
1
1
4
4
2
2
1
1
1
1
1
1
1
14
13
15
20
19
18
NOTE
16
17
Pawl assembly #5 must be

assembled with the
pawl-spring-stop on the left,
otherwise the starter will not
function.
4
3
2
1
12
9
10
11
8
6
11/2012
REGULAR
MAINTENANCE
31
SERVICING THE REWIND STARTER

WARNING
All repairs must to be carried out by qualified, professionally trained and authorized
mechanics. Only careful assembly and the respecting of the instructions found in this
SERVICE MANUAL will ensure trouble free operation.
12
12
12
12
Remove 4 hex. screws M6x20 and lock washers and detach the rewind
starter assembly.
2
Depress the cover washer and remove circlip .
Remove cover washer , friction spring and friction washer .
11/2012
Remove rewind starter parts set assy and thrust washer.
32
REGULAR
MAINTENANCE
SERVICING THE REWIND STARTER (continued)
13
15
Hold rope sheave and remove the 2 screws

along with lock
washers and the cover with plug .
Warning: Keep rope sheave firmly in hands! Risk of injury when rewind
spring unwinds!
16
21
21 through the window in the starter housing and turn rope

Pass the starter handle
sheave approx. 4 turns counterclockwise so that the rewind spring unwinds.
18 and starter grip 21 .

Remove starter sheave with starter rope
22 for signs of seizure.

Check bearing bolt
18
7
Note: If there are slight signs of seizure remove them carefully.
Check bearing bore of the rope sheave for signs of seizure.
Apply oil on the rewind spring .
22 of the rope sheave .

Apply Molykote G-N slide paste on the bearing bolt
11/2012
Note: If there are signs of seizure the rope sheave must be replaced.
22
33

19
Wind starter rope fitted with starter handle

21 counter-clockwise in the rope
sheave .
Fit rope sheave on the bearing bolt and engage it by slight turning into the
rewind spring .
Hold rope sheave firmly and turn starter housing 4 turns clockwise to pretension
the rewind spring.
Fit rope guide in the recess and pass the starter grip through the window in
the starter housing, holding the rope sheave firmly.
Fit the plug .
Fit the cover and fix it with 2 screws

and lock washers .
16
7
13
15
16
5
24
Tightening torque: 2.2 - 3 lb-ft (3 - 4 Nm)
Insert thrust washer .
Fit rewind starter parts set assy in the rewind starter.

23 must
Note: Pay attention to correct positioning. The corners of the pivot arm
point toward top / left 24 and down / right 25 .
23
25
23 of the pivot arm.

Slightly lubricate the serration
23 .
Insert the friction washer so that the serration points towards pivot arm
Fit friction spring and cover washer .
11/2012
10
34
REGULAR
MAINTENANCE
Depress cover washer and fit circlip .
21 and check whether the pawls 23 24 are moving outward.

Pull starter handle
When releasing the starter grip the starter rope must be rewound to its idle
position.
8
9
24
Note: If the pawls do not move outward, the rewind starter parts set assy
has been inserted wrongly. In this case disassemble it again and fit the
rewind starter parts set assy correctly.
23
Tightening torque: 6.6 lb-ft (9 Nm)
12
12
Start engine to check function of the rewind starter.
12
11/2012
12
Fit rewind starter assembly with 4 hex. screws and lock washers.
REGULAR
MAINTENANCE
MAGNETO
To check if ignition system is functioning,
remove spark plug and connect another
spark plug, with gap set to 3.2 mm
(0.126"), to the ignition cable. With this
plug resting on top of cylinder head,
give starter rope a normal pull. Spark
should easily jump the gap, if system is
functioning properly.
Ref. #
Part #
Description
1
2
3
4
5
6
7
8
9
R-116
R-667N-E
R-603
R-791
R-146
R-602
R-653
R-601
12-38

Flywheel magneto assembly
Fan
Stud, steel
Pulley gasket
Pulley for manual start
If no spark appears:
If spark is weak:
Qty
Check stop switch and cable for possible short

Check for shorted condenser
Check for open coil
Check for broken leads or cables
Check electronic ignition module
Check DOS
35
6
1
1
4
4
3
1
1
3
Check magneto air gap

Check electronic ignition module
9
8
7
6
11/2012
SERVICE TOOL KIT

Ref. Part
#
#
Description
R-952
Service tool kit

1
(incl. all parts listed below)
1
2
R-929
271-927
3
4
5
271-346
R-928
R-930
Flywheel holding tool

Screwdriver
Phillips No.12
Screwdriver - standard
Cap - shaft protector
Puller - crankshaft
bearing R-313
Puller - crankshaft
bearing R-333
Puller - collar coupling
Oil seal - pressing tool
Puller - magneto
Crankshaft jack
Gauge - timing
Socket wrench
14 mm (9/16")
Key - Allen
2.4 mm (3/32")
R-938
7
8
9
10
11
12
R-932
R-933
R-927
R-953
R-954-14
R-926
13
R-909
Qty
1
1
1
1
1
1
3
8
11
1
1
1
1
1
1
1
1
9
12
10
6
13
36
REGULAR
MAINTENANCE
SERVICING MAGNETO
Before replacing flywheel assembly, the ignition timing should be checked.
See "Ignition Timing".
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
_
20
21
22
23
24
25
26
R-656
Description
Armature
plate complete
(incl. parts with *)
R-665*
Mach. screw
R-611*
Lockwasher
R-637*
Flat washer
R-664*
Point & cable
condenser R-628
R-655*
Mach. screw
R-611*
Lockwasher
R-637*
Flat washer
R-661*
Coil
R-638
Mach. screw
R-611*
Lockwasher
R-637
Flat washer
R-662*
Condenser
R-659
Armature plate
(incl. R-662)
R-654*
Cap
R-636*
Grommet
R-630*
Cable-spark plug
Cable- spark plug
R-645
Rubber sleeve
R-650
Protector - spark plug
R-629
Spark plug 18 mm
R-633T
Stop switch kit
(incl. Ref. #20 to #25)
R-665
Mack, screw
R-637
Flat washer
R-611
Lock washer
C-7010-12 Stop switch assembly
12-79
Tooth lock washer
C-7010-12C Connector
R-634*
Cable stop switch
Qty
1
1. Replace flywheel assembly; make certain that flywheel keyway is aligned properly with
crankshaft key.
Important: Remove all traces of grease, oil and dirt from crankshaft taper and flywheel
bore before replacing flywheel assembly.
1
1
1
1
2. Replace lockwasher and flywheel hub nut.
2
2
2
1
3
3
3
1
1
5. Attach spark plug cable clamp.
3. Tighten hub nut to recommended torque. This is very important.

4. Attach fan cowl assembly.
6. Connect cable to stop switch.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
10 11
Note: Armature plate for pointed engine shown
14
15
16
17
12
13
R-633T
18
19
20
21 22 23 24
25
26
11/2012
Ref. Part
#
#
ENGINE OVERHAUL
SERVICE PROCEDURE
DISASSEMBLY AND ASSEMBLY

PROCEDURES OF ENGINE
This procedure outlines how to
conduct major overhaul service to
the MARK-3 engine. It lists all
instructions to replace or service the
following components:
Crankshaft-connecting rod assembly;

Crankshaft ball bearings;
Crankcase;
Oil seals;
DISASSEMBLY OF THE ENGINE FROM

THE MARK-3
1. Remove pump end assembly and flexible
buffer coupling disc.
2. Remove all wiring.
3. Remove clamp, which holds spark plug
cable to fan cowl.
4. Remove bracket R-799, which fastens to
side of carburetor shroud to engine
crankcase.
5. Remove engine from mounting frame.
6. Remove muffler.
7. Remove fan cowl with rewind starter.
8. Remove spark plug cover and spark plug.
9. Using the flywheel holding tool R-929
(Refer to the Service tool kit section), to
prevent the collar coupling from
rotating; remove nut and lockwasher
from the collar coupling.
10. Remove collar coupling from engine with
collar coupling puller R-932.
11. Remove manual starter rope pulley.
12. Remove flywheel nut and lockwasher
using flywheel holding tool R-929.
13. Remove flywheel/magneto/fan using
magneto puller R-927 and shaft
protector tool R-928.
2
Ref. #
Part #
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
R-146
R-144
R-132
R-105
12-38
R-342
R-103
R-133
R-123
R-236
R-206
R-120
A-6149P
R-130
R-113
FAST-51
R-117
R-136
C-5370-11
RA-108
R-119
R-152
Mach. screw, steel plated

Dust shield
Mach. screw, hex socket cap, steel, plated
Mach. screw, hex socket cap, steel, plated
Oil seal, 25 mm
Dowel tube, steel, plated
Crankcase gasket
Oil seal, 20 mm
Stud, steel (cylinder mounting)
Nut, hex, plated
Mounting leg
Stud, steel
Bronze gasket
Drain screw, socket cap, steel, plated
Stud, steel
Pump mounting flange
Flat washer, stainless steel
Crankcase halves set complete w/ 2 dowel tubes (R-103)
Qty
4
1
3
2
5
1
2
1
1
4
4
7
4
4
1
1
3
1
1
1
3
12
13
22
10
8
9
22
19 20 21
17
15
16
14
13
11/2012
37
18
12
38
MAJOR OVERHAUL
SERVICE
Ref. #
DISASSEMBLY OF THE ENGINE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1. Remove the key R-305.

2. Mark the position of the armature plate.
3. Remove armature plate with cables.
4. Remove the cylinder head, the cylinder
and the crankcase studs.
5. Remove piston from connecting rod.
6. Remove the machine screws, which fasten crankcase halves together.
7. Remove the rubber seal located on the
housing.
8. To separate crankcase halves on engine
with one-piece bearing, heat both
crankcase halves (on the outside face
of the crankcase around the bearing
housing portion) to a maximum of
100 C (212 F) and, using a plastic
or rubber mallet, separate crankcase
halves.
Part #
Description
Qty
R-348
Crankshaft/Conn. Rod with Kit (includes parts with *

and R-342 oil seal. R-346 and R-347 (shims not shown).
Nut, hex, plated (flywheel side)
Ball bearing, 25 mm (flywheel side) (1 piece bearing)
Shim, .0044", steel (flywheel side)
Key
Needle bearing
Gudgeon pin
L-type piston ring
Piston ring .078"
Piston with rings
Circlip
Crankshaft/connecting rod sub-assembly
Spacer, steel, plated
Shim, .006", steel (coupling side)
Ball bearing, 20 mm (coupling side) (1 piece bearing)
Coiled spring pin, steel
Coupling collar
Nut, hex, plated (coupling side)
___
R-303
R-301
R-343
R-344
R-305
R-324
R-328
R-331-1
R-331
R-332
R-329
R-341
R-334
R-306
R-333
12-18
R-315
R-302
1
2
1
1
1
1
1
1
1
1
2
1
1
1
1
4
1
1
9. Remove crankshaft with connection rod.

10.Press out both oil seals using oil seal
pressing tool R-933.
11.Remove bearings. To remove from crankshaft journals using shaft protector tool
R-928 and bearing puller tool R-938.
16
18
8
10
11
17
15
14
13
12
6
5
4
3
2
1
11/2012
MAJOR OVERHAUL
SERVICE
REASSEMBLY SERVICE FOR ENGINE

For reassembly (1 piece bearing)
1. Place both crankcase halves on a table with inner faces up.
2. Using a depth micrometer, carefully check the distance from joint-face of each
crankcase half to lower face of each bearing housing.
3. For pump side crankcase half, call this dimension (A) (see image).
4. For magneto side crankcase half, call this dimension (B) (see image).
5. Measure thickness of crankcase gasket R-133. Call this dimension (C).
6. Add (A) + (B) + (C). Call this dimension (D).
7. Measure the thickness of ball bearing R-333. Call this dimension (E).
8. Measure the thickness of ball bearing R-343. Call this dimension (F).
9. Measure the thickness of crankshaft spacer R-334. Call this dimension (G)
10. Measure the width of the crankshaft between both bearing thrust surfaces. Call this
dimension (H) (refer to image).
11. Add (E) + (F) + (G) + (H). Call this dimension (I).
12. Subtract (D) (I) and call this dimension (J).
The dimension (J) is the total axial clearance on the crankshaft. The acceptable axial clearance is from .0079 to .0118. The average acceptable axial clearance is therefore .0098.
13. Subtract (J) = (average acceptable clearance .0098) = total shim thickness
14. Put the spacer on the crankshaft (pump side).
15. Put the shims on the crankshaft magneto side (fan).
Note: The crankshaft used in the electronic ignition units does not have a lobe
ground into the crankshaft end.
16. Apply a small amount of Anti Seize (Copaslip or Loctite) on the ball bearing R-333.
17. Heat the ball bearing to a temperature of 90 C (194 F) not exceeding 100 C
(212 F).
Pistons, rings and shims optional sizes

R-307
R-308
R-309
R-310
R-311
R-312
R-344*
R-345*
R-346*
R-347*
R-332-0
R-331-0
R-331-0-1
R-321
Shim 0.008"
As req.
(coupling side)
Shim 0.012"
As req.
(coupling side)
Shim 0.016"
As req.
(coupling side)
Shim 0.020"
As req.
(coupling side)
Shim 0.031"
As req.
(coupling side)
Shim 0.040"
As req.
(coupling side)
Shim 0.004"
As req.
(flywheel side)
Shim 0.012"
As req.
(flywheel side)
Shim 0.020"
As req.
(flywheel side)
Shim 0.039"
As req.
(flywheel side)
Oversized piston
(includes rings)
Oversized piston ring 0.078"
Oversized L-type piston ring
Serrated lockwasher 12 mm
(used on old style engine)
DETERMINE THE TOTAL THICKNESS OF SHIMS

Total thickness of shims
=J-
Acceptable average axial

clearance (.0098)
J =D-I
D =A+B+C
Shim (C)
Magneto side
Pump side
Shim
I=E+F+G+H
11/2012
Bearing R-343
39
Spacer R-334
Bearing R-333
MAJOR OVERHAUL
SERVICE
18. Install the ball bearing R-333 on the crankshaft (pump side). If necessary use a
pressing tool to insert the bearing on the crankshaft.
19. Apply a small amount of Anti Seize (Copaslip our Loctite) on the ball bearing R-343.
20. Heat the ball bearing to a temperature of 90 C (194 F)
not exceeding 100 C (212 F).
21. Install the ball bearing R-343 on the crankshaft (magneto side). If necessary use a
pressing tool to insert the bearing on the crankshaft.
22. Heat the crankcases to a temperature of 90 C (194 F) not exceeding 100 C (212 F).
23. Install the new oil seals R-123 on the coupling side (pump side) and R-342 on the
magneto side (fan) of the crankcase. The oil seals must be installed from the inside to
the outside with the closed side facing the exterior of the crankcase.
24. Grease the oil seals.
25. Slide crankshaft in crankcase half (pump side). Be careful to prevent damage to lip
of oil seal.
26. Important : Ensure that the rotating part of the bearings do not come into
contact with the seals.
27. If necessary press crankshaft into crankcase half (pump side). To prevent bending of
crankshaft, be sure to always use tool R-953 (fig. 1), crankshaft jack, between webs
of crankshaft (fig. 2).
28. Install a new crankcase gasket R-133, apply some oil.
29. Slide the other crankcase half on crankshaft.
30. Align dowel tubes and verify that crankshaft jack and connecting rod are in piston
axe (fig. 3) and press crankcase halves together.
31. Cool the crankcases to a temperature of 20 C (68 F) before installing the crankcase
screws.
32. Reassemble crankcase screws and lockwashers. Tighten screws uniformly to 10 Nm
(90 inch-lbs) torque.
33. For stress relief, gently tap the two crankcase halves with a soft head hammer.
34. Turn crankshaft and check for smooth run.
35. If piston was removed, reinstall it in proper position (arrow on top of piston or balancing lumps inside piston head should be on muffler side of engine). Replace needle bearing R-324, if necessary.
36. Change cylinder head and cylinder flange gaskets (R-235 and R-238). The cylinder
head gasket must have the large band up.
37. When reassembling cylinder head, be sure the filled
part inside the head is on the muffler side of the engine, therefore the scooped-out
part will be on the carburetor side).
Important: Put carburetor side on same side of spark plug cable hole in
crankcase. Tighten cylinder head nuts to recommended torque as 23-25 Nm
(200-220 inch-lbs). Nuts should be torqued after first 10 hours of operation and
every 100 hours after.
38. Reassemble remaining parts in reverse procedure used in disassembly.
Magneto side
Pump side
Shim
Bearing R-343
Spacer R-334
Bearing R-333
11/2012
40
MAJOR OVERHAUL
SERVICE
DISASSEMBLY PROCEDURE
FOR PUMP END
1. Remove shaft nose #3, by removing
screw #1, and lockwasher #2. These
will be visible upon removal of
suction protective cap.
2. Remove screws #5, and
lockwashers #2.
3. Using tool A-1888, remove suction
cover #6.
4. Bend lockwasher #19 from locknut
#18. Using tool R-904L or 19 mm
(3/4") wrench, remove locknut and
lockwasher.
5. Remove screws #28.
6. Using bench-press and tools
A-1890, A-4097 and A-5297,
press out shaft assembly.
7. Using seal puller A-7644, remove
seal.
8. Using bench-press and tools A-1886
and A-5297, remove all impellers
and distributors. Operation is done
in jogging strokes of press ram, so
that all parts will be removed in a
group.
Ref. # Part #
Description
1
2
3
4
5
6
7
8
9
10
11*
12*
13*
14
15
16
17
-----
Mach. screw, stainless steel, nylon insert

Nose for shaft
Protective cap, suction
Mach. screw, stainless steel
Suction cover with bronze bearing
O-ring
Gasket 1 1/2" (38 mm)
Cap for priming port
Retainer for priming cap
Grease fitting
Extension for grease fitting
Set screw, stainless steel
Protective cap, discharge
Plug, 1/8" NPT, brass
Pump body, 12-16 / 12-16S (4-stage)
Mechanical rotary seal
Thread protector 2" NPSH (suction) (incl. gasket)
Thread protector 1 1/2" NPSH (discharge) (incl. gasket)
Thread protector 1 1/2" NH (discharge) (incl. gasket)
1/4-turn quick-connect adaptor (discharge) (incl. gasket)
12-42
12-38
12-13
A-5537
12-39
12-12A
12-27
12-43
12-10
A-5538
12-29
12-87
FAST-722
A-5536
12-73
12-8
12-28NS
A-2688
ADP-A-FM15S
A-7465
FA-4
Qty
11*
12*
14
15
10
11/2012
1
3
1
9
1
1
8
1
1
1
1
1
1
1
1
1
1
1
1
Optional
Optional
Optional
Optional
*Pump ends with the sealed double row ball bearing (12-48S) exclude
the set screw FAST-722, the grease fitting 12-29 & the extension 12-87.
41
13*
16
17
42
MAJOR OVERHAUL
SERVICE
Ref.
#
18
19
Part
#
12-50**
12-49**
20
21
22
23
24
25
26
12-11**
12-9
12-27
12-7**
12-6
12-26
12-48*
Description
Locknut stainless steel 1

Lock washer,
1
stainless steel
Impeller
1
Distributor
2
O-ring
2
Impeller
3
Distributor
1
O-ring
1
Double row ball
1
bearing
Sealed double
1
row ball bearing
Retaining ring
1
for bearing
Mach. screw,
6
stainless steel,
nylon insert
Shaft and collar
1
assembly, 4-stage
Coupling buffer
1
Shaft sub-assembly,
4-stage, with impellers
(incl. parts with * and **,
7 items)
Shaft sub-assembly, 4-stage
(incl. parts with *, 3 items)
26a 12-48S
27
12-3*
28
12-25
29
12-2C*
30
--
12-17
12-2D
--
12-2E
Qty
ASSEMBLY PROCEDURE FOR PUMP END

1. Slide bearing retaining ring #27 on shaft with plain face toward coupling collar.
2. Press bearing #26 on shaft.
3. Press rotary seal #17 in pump body using sleeve A-4329. This should be done
carefully.
4. Carefully pass end of shaft assembly through rotary seal bore. Make sure that the flat
sections of the shaft line up with the rotary seal flat sections. Gently press down the
shaft until ball bearing rests firmly against shoulder in pump body.
5. Attach retaining ring #27 to pump body using six screws and tighten evenly and firmly.
6. Slide impeller #23 onto shaft, and engage with seal.
7. Place O-ring #25 in groove of distributor #24. It is important to smear the new
O-rings with a suitable lubricant. This will facilitate the assembly.
8. With open end of pump body in vertical position, carefully lower distributor #24
until it rests on bottom of body.
9. Slide impeller #23 into position, aligning with shaft.
10. Place O-ring #22 in groove of distributor #21.
11. Place distributor on open end of body, then using bench press and assembly tool
A-1884, apply several light, downward strokes of press ram until distributor "drops"
into body. Distributor must then be positioned by hand as before.
12. Slide impeller #23 into position, aligning with the other impeller.
13. Repeat steps 10 and 11 for the remaining distributor.
14. Slide impeller #20 into position, aligning with previous impeller.
15. Place lockwasher #19 on shaft with locating tab in milled groove.
25
22
26a
22
19
20
21
23
23
21
23
26
27
28
29
30
24
11/2012
18
MAJOR OVERHAUL
SERVICE
NOTE
16. Screw locknut #18 onto shaft. When tightening the nut, do not use excessive force as
this may result in failure of the seals, drive bushing or impellers. Do not forget to
secure the shaft from rotating. Bend lockwasher up onto one flat of the hexagon
locknut at a position approximately 180 from the milled slot in the shaft.
17. Place O-ring #7 in groove of suction cover #6, then bench press the cover into the
pump body until it rests on face of first distributor. A gap of approximately 0.794 mm
(1/32") between nozzle flange and end of body, is normal.
18. Attach suction cover to body by using the #5 screws and lockwashers #2. Tighten
screws evenly and firmly.
19. Attach shaft nose #3 using lockwasher #2 and screw #1. Tighten screw evenly and
firmly.
20. Check gasket in the priming cap #9 and replace if damaged.
21. Reinstall the suction and discharge thread protectors (if equipped).
22. Reinstall caps on suction and discharge inlets.
Use a clean gun filled with fresh grease. Remove dirt from grease fitting
before applying grease gun. Grease should be pumped slowly into bearing
chamber until fresh grease appears around bearing retaining ring.
Wipe off excess grease.
Use only water repellent ball bearing grease, preferably a grease that has a
rust inhibitor.
A grease relief valve (old style only) has been provided to prevent pressure
buildup on the rotary seal, should the fresh grease not be able to flow
completely through the bearing, due to old grease being hard packed, etc.
TOOL KIT FOR

PUMP END
Description
ASSEMBLY PROCEDURE FOR PUMP END (continued)
NOTE: Pump ends (12-16) with the double row ball bearing (12-48) should
be greased after every 8 hours of operation.
The maintenance-free sealed

bearing (12-48S) eliminates pump
failure dangers related to improper
greasing by completely removing the
need to grease the pump end bearing.
No greasing is necessary for pump
ends (12-16S) which have a sealed
bearing.
Ref. Part
#
#
DO NOT use graphite grease, or a pressurized grease gun.
Qty
A-2356
Tool kit for pump end
A-1884
2
3
4
5
6
A-4329
A-4097
A-7644
A-1888
A-1890
A-1886
R-904L
A-1887
10
A-5297
Pressing sleeve
for distributor
Seal pressing sleeve
Shaft protector
Seal puller for 12-28NS
Suction cover puller
Pressing pin for
shaft removal
Pressing pin for
distributor removal
Wrench for
lock nut/spark plug
Shaft installation
aligning guide
Pump support tool
1
1
1
1
1
1
2
3
1
1
1
1
9
11/2012
43
10
44
MISCELLANEOUS
6
FRAME
Ref. # Part #
--1
2
3
4
5
6
7
8
9
10
11
12
13
--
Description
C-5200N
C-5200N-15
Frame kit (incl. all parts)

Frame hardware kit (incl. all
parts except C-5201 frame)
C-5200-8
Bolt, hex, stainless steel
D-5269-7
Flat washer, stainless steel
C-5200-7R
Rubber spacer for fuel connector
C-6650-14
C-4506-3
Rubber bumper
A-6149P
Mounting leg
A-4005
Mounting pad
A-6179
Rubber ring
C-5200-5
Rubber washer
C-5201
Frame
C-5200-6
Flat fender washer, steel, plated
R-111
C-5200-12
C-5200RK-11 Frame kit parts list
Qty
--2
2
2
2
2
4
2
8
4
1
4
4
4
1
7
1
2
8
9
3
4
10
5
8
11
12
13
QUICK-CONNECT FUEL LINE

Description
--
R-1114
1
2
3
4
5
6
7
8
9
10
11
12
13
14
C-5200-8
D-5269-7*
R-798*
R-706*
R-709*
C-5200-7R*
C-6650-14*
A-7486
A-7487
R-712
R-732
FA-552Q
FA-451
12-401B-NS
15
12-65
Quick-connect fuel line

(includes parts with *)
Hex bolt
Flat washer
Fuel line - plastic
Body quick-connect male
Elbow
Spacer - rubber
Hex lock nut
Dust cap male connector
Dust cap female connector
Handle quick connect
Connector
Fuel air transport tank
Fem. quick connect
Hose-fuel supply
with priming bulb
Coupling swivel
Qty
14
1
2
2
1
1
1
2
2
1
1
1
1
1
1
1
15
10
3
1
2
4
8
11
6
7
9
12
13
11/2012
Ref. # Part #
NOISE REDUCTION MUFFLER

Ref. # Part #
1
2
3
4
5
6
7
8
Description
R-237
R-151
Muffler gasket
Flatwasher,
steel, plated
R-150
Lock nut,
steel, plated
R-229
Muffler
C-5370-11 Flat washer,
stainless steel
R-119
Lock washer,
steel, plated
RA-108
Bolt, hex, steel,
plated
PART-205 Spark arrestor
(incl. screw)
45
Qty
1
1
1
1
1
1
1
1
6
PART-205
USFS Approuved Spark arrestor
7
2
4
5
11/2012
DECARBONISING
After several hours of normal operation, carbon deposits will form on piston crown, cylinder
head, in the cylinder exhaust port and around piston rings and in the ring grooves, causing
erratic and faulty operation. The piston skirt may also show signs of gum and varnish deposits.
To decarbonise, the cylinder head, cylinder and piston should be removed. All carbon
deposits should be carefully removed, particularly from the piston ring grooves. After
removing carbon, wash all parts in a suitable solvent, then dry with compressed air. On
reassembly, always use new piston rings.
After every 100 hours of operation, or more often if a loss of power is observed,
the engine should be decarbonised.
To decarbonise the engine, proceed as follows:
1. Remove muffler. If muffler is very dirty internally or appears burned or cracked, it should
be replaced with a new muffler.
2. Remove cylinder head and cylinder head gasket.
3. Rotate crankshaft until piston is at bottom dead centre.
4. Using a brass scraper tool, carefully scrape carbon deposit from exhaust port. During
this operation, tilt engine so that deposits will not fall into combustion chamber.
5. Use suitable brass tool to push out any carbon deposit which may have formed in the
hole provided in the cylinder liner for bypass.
6. Rotate crankshaft until piston is at top dead centre.
7. Use a stiff (not wire) brush to remove loose, flakey carbon from top of piston. Do not
remove hard deposit of carbon, as this layer forms a natural heat insulator to protect
the piston crown.
8. Remove all carbon deposits from cylinder head.
9. Replace cylinder head. Tighten nuts uniformly to recommended torque
23-25 Nm (200-220 inch-lbs) value. Always use a new cylinder head gasket (cylinder
head gasket must have the large band up).
10. Check and replace muffler gasket if worn or damaged. Reinstall muffler.
46
TECHNICAL SPECIFICATIONS
TORQUE VALUES
ENGINE
Spark plug
Cylinder head nuts
Crankcase assy. screws
41 Nm / 360 inch-lbs (30ft-lbs) (41Nm)

23-25 Nm / 200-220 inch-lbs
Should be retorqued every 100 hours of operation.
44-45 Nm / 390-400 inch-lbs
11-14 Nm / 100-120 inch-lbs
Crankshaft with no keyway at PTO end should be
torqued to 19-21 Nm / 175-185 inch-lbs.
11-12 Nm / 100-110 inch-lbs
PUMP
Retaining ring screws
Shaft nose screw
Nut #12-50
Suction nozzle screws
6.7-7.3 Nm / 60-65 inch-lbs

7.9-8.5 Nm / 70-75 inch-lbs
28-29 Nm / 250-260 inch-lbs.
7.9-8.5 Nm / 70-75 inch-lbs
Flywheel hub nut

Collar coupling nut
PUMP
Impeller #12-7 diameter
Impeller #12-7 width
Impeller #12-11 diameter
Impeller #12-11 width
Distributor #12-6 diameter
Distributor #12-6 width
Distributor #12-9 diameter
Distributor #12-9 width
Pump inside depth
Pump ball bearing housing
Nozzle bushing
bearing housing
Buffer thickness (#12-17)
Shaft ball bearing support
Shaft bushing bearing support
Shaft maximum run-out
93.22 mm 0.13 / 03.670" 0.005

38.86 mm 0.05 / 1.530" 0.002
93.22 mm 0.13 / 03.670" 0.005
34.11 mm 0.05 / 1.343" 0.002
123.39 mm-123.47 mm / 04.858"-4.861"
31.31 mm 0.05 / 1.234" 0.002
0123.39 mm-123,47 mm / 04.858"-4.861"
34,11 mm 0,05 / 1.343" 0.002
108,10 mm 0,05 / 4.256" 0.002
51.99 mm-52.02 mm / 2.047"-2.048"
19.037 mm-19.063 mm / 0.7495"-0.7505"
8.25 mm-8.89 mm / 0.325"-0.350"
25.004 mm-25.011 mm / 0.9844"-0.9847"
12.687 mm-12.700 mm / 0.4995"-0.5000"
0.0889 mm / 0.0035"
STANDARD CYLINDER SPECS

61.95 61,96 mm 2.439 2.4394
62.00 62,01 mm 2.4409 2.4413
1 to 2 Micron 39 to 78 Microinches
OVERSIZE CYLINDER SPECS

(new sleeve for oversize piston)
Cylinder bore (oversize)
Cylinder bore (hone)
Surface Roughness
62.45 62,46 mm 2.4587 2.4591

62.50 62,51 mm 2.4606 2.4610
1 to 2 Micron 39 to 78 Microinches
CLEARANCE DATA AND LIMITS

ROTAX
ENGINE
Spark plug type
Spark plug gap
Breaker points gap
Ignition timing limits
Ignition timing - nominal
Magneto air gap
Condenser capacity
Normal current for testing coil
Crankshaft axial clearance
Cylinder Surface Roughness
Piston dia. - nominal
Piston dia. - oversize
Piston / cylinder clearance
Wear limit
Cylinder taper
Cylinder out of round
Piston ring end gap (new ring)
Wear limit
Piston pin hole dia. (in piston)
Piston pin dia.
Crankshaft halves run-out
Crankshaft bearing seat dia.
(on crankshaft coupling side)
Wear limit
(on crankshaft flywheel side)
Wear limit
Crankcase bearing seats dia.
(both sides)
Wear limit
Connection rod inside dia.
(for piston rim bearing)
Ring / piston groove clearance
Wear limit
(measured on rectangular rings only)
Stroke
Bosch M4AC18 mm
0.41-0.51 mm / 0.016"-0.020"
0.35-0.45 mm / 0.014"-0.018"
2.54-4.01 mm / 0.100"-0.158" BTDC
2.54 mm / 0.100"BTDC
0.25-0.33 mm / 0.010"-0.013"
0.15-0.19 mF
1,0 amp. nominal / 2,0 amp. max.
0.2-0.3 mm / 0.0079"-0.0118"
62.50-62.51 mm
1-2 Micron / 39-70 microinches
61.94 mm/2.4386"
62.44 mm / 2.4583"
0.06-0.08 mm / 0.0024"-0.0032"
0.20 mm / 0.0079"
max. 0.08 mm / 0.0032"
max. 0.05 mm / 0.0020"
0.20-0.35 mm / 0.0079"-0.0138"
1.00 mm / 0.03937"
18.001-18.005 mm / 0.7087"-0.7089"
17.997-18 mm / 0.7085"-0.7087"
0.03 mm/0.0011"
20.002-20,011 mm / 0.7875"-0.7878"
20 mm / 0.7874"
25.002-25,011 mm / 0.9843"-0.9847"
25.000 mm / 0.9843"
51.95-51.96 mm / 2.0453"-2.0457"
51.98-51.99 mm / 2.0465"-2.0469"
21.997-22.005 mm / 0.8660"-0.8663"
0.04-0.11 mm / 0.0016"-0.0043"
0.2 mm / 0.0079"
61 mm / 2.40"
SOLID STREAM NOZZLES (Approximate reach of stream)

Nozzle Pressure
Nozzle Diameter
6.4 mm (1/4")
kPa
138
276
414
552
690
827
965
psi
20
40
60
80
100
120
140
M
13.1
17.7
20.1
22.0
22.9
23.5
23.8
9.5 mm (3/8")
ft
43
58
66
72
75
77
78
M
15.2
20.1
22.9
24.4
25.3
25.9
25.9
ft
50
66
75
80
83
85
85
12.7 mm (1/2")
M
17.4
22.3
25.0
26.8
28.0
28.7
28.7
ft
57
73
82
88
92
94
94
MAXIMUM PERFORMANCE
Pressure
kPa
345
517
690
1034
1379
1724
2069
2448
2620
psi
50
75
100
150
200
250
300
350
380
Discharge Flow
L/min
337
314
295
246
197
144
95
34
0
IMP GPM
74.1
69.1
65
54.1
43.3
31.6
20.8
7.5
0
US GPM
89
83
78
65
52
38
25
9
0
METER HEAD OF WATER AND EQUIVALENT PRESSURE

Head of
Water
Meters
1
2
3
4
5
6
7
8
9
10
Pressure
kPa
9.8
19.6
29.4
39.2
49.0
59.8
68.6
78.4
88.2
98.0
Head of
Water
Meters
11
12
13
14
15
16
17
18
19
20
Pressure
kPa
107.8
117.6
127.4
137.2
147.0
156.8
166.6
176.4
186.2
196.0
Head of
Water
Meters
21
22
23
24
25
26
27
28
29
30
Pressure
kPa
205.8
215.6
225.4
235.2
245.0
254.8
264.6
274.4
284.2
294.0
*** Performance will vary from location to location. Altitude dependant.

11/2012
(new sleeve for standard piston)

Cylinder bore (standard)
Surface Roughness
APPENDICES
47
CONVERSION INSTRUCTIONS
B-7595, MARK-3 CONVERSION KIT

FROM POINTS TO CDI
Applies to MARK-3 units with the
points ignition
1. Take the 12-16 / 12-16S pump
end off.
2. Remove the fuel quick connect
from the frame.
3. Disconnect the fuel line from the
carburetor.
4. On the carburetor (R-1115), rotate
the fuel strainer cover (R-1017) by
180 deg. (position A to position B)
(FIG. 3 #4).
FIG. 1: MARK-3, points style
FIG. 2: MARK-3 with electronic ignition
FIG. 3 #4
FIG. 4
5. Remove the frame from the

engine (FIG. 4).
6. Copy the whole pattern
(17/64 dia.) on the other leg,
at 2 5/8 from the original
holes (FIG. 5).
FIG. 5
17
11/2012
2 5/8
/64
(2 HOLES)
48
APPENDICES
CONVERSION INSTRUCTIONS (Continued)
7. Remove the spark plug cover

(R-413).
8. Remove the wire loom & cable
ties to uncover the cutout switch
wire. (If applicable).
9. Disconnect the cutout switch
wire from the blue female bullet
connector and cut the blue
connector off. (Color may vary)
(FIG. 6 #9).
10. Remove the clamp (R-409),
lock washer (R-521) and screw
(R-408) that hold the ignition
wire on the fan cowl.
(FIG. 6 #10)
FIG. 6
11. Remove the fan cowl (R-411)

(FIG. 7 #11).
12. Remove the pulley - manual
starter rope (R-601)
(FIG. 7 #12).
13. Remove the gasket (R-653)
(FIG. 9 #13).
14. Remove the hex nut (R-302) that
locks the flywheel assembly in
place.
FIG. 7
15. Use the flywheel holding tool
(R-929), the puller magneto
(R-927) and an adjustable
wrench to remove the old
flywheel/magneto assembly
(R-667) (FIG. 8).
11/2012
FIG. 8
APPENDICES
16. Remove the old Magneto from

the Flywheel and Fan assembly.
17. Install the new Magneto onto
the Flywheel and Fan assembly.
Use Lock-Tite Threadlocker
(Green).
18. Remove the old Armature Plate
Assembly (R-656) (FIG. 9 #18).
19. Cut the black female blade
connector on the green wire
from the new Armature Plate
assembly.
FIG. 9
20. Install the new Armature Plate

assembly. Pass the green wire
in the grommet of the existing
hole the engines crank case
(FIG. 10 # 20, FIG. 13 # 20).
Refer to installation instructions
of the electronic ignition on how
to adjust the timing.
21. Install the new Flywheel /
Magneto assembly and tighten
the Hex Nut (R-302) (FIG. 11).
Important:
Torque 390 400 inch lbs.
FIG. 10
11/2012
FIG. 11
49
50
APPENDICES
22. Install the gasket (R-653)

(FIG. 12 #22).
23. Install the Pulley Manual
Starter Rope (R-601)
(FIG. 7 #12).
24. Install the Fan Cowl (R-411)
onto the engine body, muffler
side first to have as much space
and play as possible
(FIG. 13 #24).
Do not install the top lock nut,
on the Air Filters side. It will be
used as a ground, at a later step.
FIG. 12
25. Install a red female bullet

connector (PART-255) on the
green wire from the new
Armature plate (FIG. 14 #25).
26. Insert both the cut-out switch
wire and the small 3 long wire
in the red male bullet connector,
crimp them together with a
blue female bullet connector
(C-7010-12C). Insert a piece of
shrink tubing onto the wires
before crimping them together
(FIG. 14 #26).
FIG. 13
11/2012
FIG. 14
APPENDICES
27. Install the frame back onto the

engine.
28. Install the fuel quick connect
(or brass fuel block on some
models) on the frame, using
the new holes you drilled in
step 6 (FIG. 15 #28).
29. Connect the fuel line on the Fuel
Strainer Cover (R-1017) you
rotated in step 4 (FIG. 3 #4).
30. Install the electronic ignition box
assembly (B-7592) in the old
holes of the fuel quick connect
on the frame (FIG. 16 #30).
FIG. 15
Make sure to leave at least 1/16

gap between the electronic
ignition box assembly (B-7592)
and the carburetor shroud
(R-790). It might be necessary
to sand the carburetor shroud
down to ensure a reasonable
gap. You may have to remove
the carburetor shroud to install
the electronic ignition box on
the frame.
31. Connect the on/off switch to the
cutout switch Y wire
(See step 26).
FIG. 16
32. Connect the 3 long wire (from

step 26) to the black stop switch
wire coming out of the electric
ignition box. Connect both
wires together.
11/2012
33. Connect the green armature

plate wire to the green STATOR
wire coming out of the electric
ignition box (FIG. 17 #33).
FIG. 17
51
52
APPENDICES
34. Connect the red (ground) wire

of the electronic ignition box
to the stud of the fan cowl
(FIG. 18 #34).
35. Install the rubber covered clamp
on the stud of the fan cowl,
then the missing lock nut from
step 24 (FIG. 18 #35).
36. Connect the spark plug ignition
cable from the electronic ignition
box to the spark plug.
37. Use the clamp (R-409), screw &
lock washer (R-408) to attach
the ignition cable on the fan
cowl of the MARK-3 just above
the cutout switch reset lever
(FIG. 19).
FIG. 18
38. Install the 9 long wire loom

(FIG 20 #38A), insert all the
wires and connectors inside and
secure it with 3x 4 long cable
ties (FIG. 20 #38B).
FIG. 20
11/2012
FIG. 19
APPENDICES
53
INSTALLATION INSTRUCTIONS
PROCEDURE:
Remove old flywheel and armature
plate.
Fit the new armature plate so that

the long holes are aligned ,
then turn it approx. 1 mm
counter-clockwise, then tighten
the 3 screws.
Turn crankshaft until the piston is

3.75 mm before top dead centre,
measuring through the spark plug
hole with a dial gauge. For the
final dynamic ignition timing
check make an ink mark on the
coupling buffer 12-17 as
well as on the flange pump
mounting R-136.
Fit electronic box.
Start engine and check ignition
timing with a stroboscopic lamp.
The 2 marks previously
made must correspond at
3000 4000 r.p.m.
If the 2 marks do not correspond,
remove flywheel and loosen the
3 screws of the armature plate,
turn armature plate slightly in the
direction needed. Repeat the
procedure until the marks
correspond.
11/2012
Seal rubber grommet with

Silastic.
54
APPENDICES
INFORMATION ON MECHANICAL CUT-OUT SWITCH FOR PREVIOUS

MARK-3 MODELS
Cutout Switch Adjustment (Static)
The cutout switch must be adjusted when installed in the fan cowl. This is necessary
because slight changes in the shape of the mounting plate occur when fastened in position
on the fan cowl.
Check that, with the air vane in the approximate centre of its travel, the spring attachment
holes "line up" with the pivot to form a a straight line (see FIG. 1). All brackets and pivot
should be perpendicular with the face of the plate.
Cutout Switch Adjustment (Dynamic)

1. Setup pump unit close to water supply. Use a 2 m to 3 m (6' to 10') suction hose with
footvalve attached. Connect a short length 2 m to 3 m (6' to 10') of discharge hose to
pump outlet. Attach a calibrated nozzle having a 12.7 mm (1/2") diameter orifice.
2. After starting and warming up engine thoroughly, increase to maximum recommended
power, then lift footvalve out of water supply. Engine will speed up then stop suddenly,
indicating the automatic cutout switch is functioning.
Should the switch not cutout after 1-2 seconds, while engine is running at increased
speed, close throttle and toggle switch immediately, otherwise serious engine damage
may result.
Assuming that cutout is functioning, then the speed setting of the switch should be checked
to make sure that it is not set too low or too high.
Use a reliable tachometer to check engine RPM.
3. Located in the upper centre of the outer surface of the fan housing, is a small socket
head adjustment screw. By using a 1/16" Allen key (tool R-909) and turning this screw
1/2 turn clockwise will increase the cutout speed setting approximately 150 RPM. A
1/2 turn counterclockwise will decrease speed setting approximately 150 RPM. After
each adjustment, recheck the actual speed at which cutout switch operates until proper
setting is obtained.
If a reliable tachometer is not available, then the cutout switch may be roughly calibrated
as follows:
Use a 3 mm (1/8") orifice tip screwed to nozzle. After warming up engine thoroughly,
increase to full throttle, then turn adjustment screw slowly counterclockwise until switch
cuts out and stops engine. Now turn screw one full turn clockwise and leave it in this
position.
The cutout switch will now operate automatically to stop engine should pump run out of
water, lose prime, etc. The switch will not interfere with normal operation of the unit and
will also allow the use of small nozzle tips as well as complete pump shut-off for short
periods of time.
Stop Switch Kit (R-633T)
20
21
22
23
24
25
R-665
R-637
R-611
C-7010-12
C-7010-12C
R-634*
Mach. screw
Flat washer
Lockwasher
Stop switch assembly
Connector
Cable stop switch
1
1
1
1
1
1
R-633-T
20
21 22 23
24
25
11/2012
FIG. 1
Initial setting: A preliminary setting can be made by placing on the vane an object
sufficiently heavy to cause the vane to just leave the stop and start to move towards the
contacting position. A 2.5 oz (70 g) weight is used to approximate the setting during
assembly. The final calibration must be made with the engine running.
APPENDICES
55
B-6289 DOS INSTRUCTION SHEET

2
3
The following items are included in the B-6289:

Ref. #
1
2
3
4
5
6
Part #
B-6289-2
B-6289-5
B-6289-1
B-6289-6
B-6289-3
B-6289-4
Description
DOS bracket
DOS module
7
Installation
11/2012
To install the DOS, you will need the following tools:

Flat screwdriver
Center punch
10 mm wrench
Phillips screwdriver
#30 drill bit
Cable ties
Cutters
M4 x 0.7 tap & holder
Pencil or marker
11/32 wrench or socket
Qty
1
1
1
4
2
2
56
APPENDICES
B-6289 DOS INSTRUCTION SHEET (continued)
STEP 1
Remove the ON/OFF
switch.
Cut the upper cable tie
and partially remove the
split loom.
STEP 2
Disconnect the splitter
wire (bullet connector
male) from the Stop
Switch wire coming from
the CDI module.
STEP 3
Remove the "RESET"
decal.
11/2012
Remove the ignition cable

clamp.
APPENDICES
STEP 4
Make a horizontal mark on
the bracket 1" from the top.
Place the bracket on the fan
cowl and line up the 1"
mark with the cylinder head
(as shown in the picture).
Make sure that the bracket
lays flat on the side of the
fan cowl. Make sure that
the countersunk hole at the
center of the bracket is not
too close to the edge of the
fan cowl.
Once installed, the DOS and
the bracket should clear the
spark plug cover and the
carburetor shroud.
STEP 5
Mark the three holes (to be
drilled and tapped later).
Center punch the three
holes.
STEP 6
Loosen up the fan cowl and
rotate it as shown.
11/2012
Cut the cut-out switch wire

and remove the B-6288,
mechanical cut-out switch
including the reset lever.
57
58
APPENDICES
B-6289 DOS INSTRUCTION SHEET (continued)
STEP 7
Drill the marked three
holes with a #30 (.1285")
drill bit.
Tap the three holes
M4 x 0.7.
STEP 8
Relocate the fan cowl at
its proper
location and tighten nut.
Install the bracket using
three screws and two
tooth lock washers.
Install the DOS using two
screws and two tooth lock
washers. Make sure the
DOS is strongly mounted
on the bracket to ensure
proper ground contact.
STEP 9
Connect the DOS wire
to the stop switch wire
coming from the CDI
module.
Secure the wiring.
11/2012
Re-install the split loom

around the cables and
secure with a cable tie.
APPENDICES
Starting the engine:
Before starting the engine, it
is recommended to pull the
starter rope and crank over
the engine a couple of times
in order to charge up the
DOS. This will facilitate the
starting. The LED will light
up while the DOS is being
charged.
Start the engine as directed
in the MK-3 Instruction &
Service manual. (Note that
there is no ON switch.)
Stopping the engine:
To stop the engine, press the
OFF button until the engine
shuts down.
Overspeed condition:
If the engine starts to
overspeed, the DOS will
automatically shut down
the engine.
Always make sure that
the cause of the overspeed
condition has been
identified and corrected
before attempting to
restart engine.
11/2012
When attempting to restart

the engine (after overspeed
condition or pressing OFF
button), wait 10 seconds
from the time the engine
shut down; this will enable
the DOS to reset itself.
Failure to wait the
prescribed duration of time
will make it difficult to
impossible to start the
engine. It may also lead to
a flooding condition.
OPERATION
59
60
APPENDICES
IGNITION TIMING TOOL R-954-14

Instructions
To check ignition timing,

proceed as follows:
1. Inspect breaker points. Clean
or replace if necessary, then
reset gap. Refer to Servicing
Magneto in the MARK-3
Service Manual.
2. Remove spark plug.
3. Slowly screw timing gauge
(R-954-14) into spark plug opening, while rocking crankshaft
back and forth until piston just
touches bottom of gauge. Piston
is then at top dead centre.
Cylinder head
4. Leave timing gauge in this

position.
5. Rotate crankshaft approximately
90 counterclockwise.
6. Insert 0.0015 (0.04 mm) feeler
gauge between breaker points.
7. Mark cylinder head fin with a
small mark aligned with the
zero 0 on the gauge. Screw
timing gauge in to 0.147
(3.734 mm), or almost three
complete revolutions (0.050
per revolution).
R-954-14
Ignition timing gauge
8. Slowly rotate crankshaft clockwise until piston comes to rest

against gauge plunger.
9. Timing is correct if the 0.0015
(0.04 mm) feeler gauge slips
easily from between the points
as the piston touches the
plunger. If timing is incorrect, it
can be corrected by rotating the
armature plate assembly clockwise to retard, counterclockwise
to advance the timing.
10.Reinstall flywheel and set air
gap between the flywheel
magnets and ignition coil to
0.010 (0.254 mm).
11/2012
Note: Do not exceed recommended

gap limits when setting breaker
points.
61
11/2012
PARTS INDEX
PART #
DESCRIPTION
PAGE
PART #
DESCRIPTION
PAGE
12-2C
Shaft - riveted assembly
42
A-1888
Puller - suction nozzle
42, 43
12-2D
Shaft sub-assembly of 7 items
42
A-1890
Pressing pin - shaft removal
42, 43
12-2E
Shaft sub-assembly of 4 items
42
A-2356
Maintenance tools for pump
43
12-3
Retaining ring for bearing
42
A-2388
Pump test kit
17
12-6
Distributor
42
A-2389
Pump test kit box
17
12-7
Impeller
42
A-2390
Pressure gauge adaptor, 38 mm (1 1/2)
17
12-8
Pump body
41
A-2390A
Shut-off valve
17
12-9
Distributor
42
A-2391
Rubber hose assembly with A-2391B
17
12-10
Cap for priming port
41
A-2391B
Adaptor
17
12-11
Impeller
42
A-2392
Pressure gauge, 0-2800 kPa (0-400 psi)
17
12-12A
Suction nozzle (includes 12-40)
41
A-2395
Brass calibrated nozzle tip set
17
12-13
Nose for shaft
41
A-2688
Thread protector 51 mm (2)
41
12-17
Coupling - buffer
21, 42
A-2924
Reset rod
29
12-25
Mach. screw flat Phillips, stainless
42
A-2926
Cable
29
12-26
O-ring
42
A-3023
Carburetor adjusting tool
19
12-27
O-ring
41, 42
A-4005
Mounting pad
43
12-28NS
Mechanical rotary seal
41
A-4027
Pin - index
28
12-29
Grease fitting
41
A-4028
Spring
28
12-38
Lockwasher
29, 30, 35, 37, 41
A-4030
Throttle decal (english)
28
12-39
Mach. lock screw, Fillester, stainless
41
A-4097
Protector - shaft
43
12-40
Bushing bearing, bronze
41
A-4329
Pressing sleeve - rotary seal assembly
12-42
Mach. lock screw, Fillester, stainless
41
A-4452
Link for lever side
15
12-43
Gasket, 38 mm (1 1/2)
41
A-4453
Eye-bolt
15
12-48
Double row ball bearing
42
A-4454
Clevis pin for eye-bolt side
15
12-48S
Sealed double row ball bearing
42
A-4455
Clevis pin for lever side
15
12-49
Lockwasher, stainless
42
A-4456
Knob for tension adjustment
15
12-50
Lock nut, stainless
42
A-4460
Lever
15
12-73
Plug, brass
42
A-5297
Support tool
12-79
Lockwasher, star type
28
A-5536
Protective cap, discharge
41
12-87
Extension for grease fitting
41
A-5537
Protective cap, suction
41
12-401B-NS
Hose-fuel supply with priming bulb
43
A-5538
Retainer for priming cap
41
212-170P
Clamp assembly
15
A-6510
Decal for electronic ignition
20
271-346
Screwdriver - standard
35
A-6149P
Mounting leg
37, 43
271-488
Bag - tool roll
19
A-6179
Ring - rubber
43
271-923
Wrench - adjustable 203 mm (8")
19
A-7486
Dust cap male connector
43
271-927
Screwdriver - Phillips No 1
35
A-7487
Dust cap fem. connector
43
A-1884
Pressing sleeve - distributor assembly
42, 43
A-7589
Mounting block, electronic ignition
20
A-1886
Pressing pin - distributor removal
42, 43
A-7644
Seal puller for 12-28NS
A-1887
Guide - shaft aligning, body
42, 43
B-2428-6
Hex lock nut
42, 43
42, 43
41, 43
29
62
PARTS INDEX
PART #
DESCRIPTION
PART #
DESCRIPTION
PAGE
B-2920-6
Flat slotted bolt
29
R-119
Lockwasher
B-2920-23
Grommet
29
R-120
Hex nut
28, 37
37, 39
28, 29, 37, 44
B-4024
Quadrant for throttle lever
28
R-123
Oil seal 0.788"
B-4036-12
Mach. screw hex socket
28
R-130
Stud - mounting leg
37
B-4457
Clamp - bottom half
15
R-132
Mach. screw, steel plated
37
B-4461
Clamp - top half
15
R-133
Gasket for crankcase
37, 39
B-5562-18
Plastic coated clamp
20
R-136
Flange - pump mounting
21, 37
B-6288
Cutout switch assembly
18, 29, 46, 49
R-144
Shield - dust
37
B-6289
Digital Overspeed Switch (DOS)
18, 47-51
R-146
Mach.screw
35, 37
B-7595
MARK-3 conversion kit (Point to CDI)
20
R-149
Lockwasher
28
C-1933
Calibrated nozzle 12,7 mm (1/2)
17
R-150
Hex lock nut
14, 28, 29, 44
C-4506-3
Bumper - rubber
43
R-151
Flat washer
C-5200-5
Washer - rubber
43
R-152
Crankcase halves set
C-5200-6
Flat washer
43
R-206
Flat washer
37
C-5200-7R
Spacer - rubber
43
R-229
Muffler
44
C-5200-8
Hex bolt
43
R-233
Cylinder head -18 mm
23, 28
C-5200-12
Hex bolt
43
R-235
Gasket - cylinder flange
28, 39
C-5200N
Mounting frame assembly
43
R-236
Stud - cylinder mounting
C-5201
Frame
C-5370-11
Flat washer
C-6650-14
29, 44
37
37
43
R-237
Gasket - muffler
37, 44
R-238
Gasket - cylinder head
Hex lock nut
43
R-257
Cylinder
28
C-7010-12
Stop switch assembly
14
R-270
Cast iron sleeve
28
C-7010-12C
Connector
14, 36
R-271
Electronic Ignition conversion kit
20
D-2902-9
Grommet
20
R-301
Lockwasher
38
D-5269-7
Flat washer
43
R-302
Hex nut (coupling side)
38
FA-552Q
Fuel air transport tank
43
R-303
Hex nut (flywheel side)
38
FAST-18
Bolt, hex, steel plated
20
R-305
Key
38
FAST-20
Bolt, hex, steel plated
20
R-306
Shim 0.006" (coupling side)
38
FAST-510
Flat washer, steel plated
20
R-307
38, 39
MK-138
Gasket 51 mm (2")
40
R-308
38, 39
MTR-1000
Hours meter with RPM
28
R-309
38, 39
PART-37
Female disconnect terminal, insulated
20
R-310
38, 39
R-103
Dowel tube
37
R-311
38, 39
R-105
Mach.screw
37
R-312
38, 39
R-111
Lockwasher
43
R-315
Collar coupling
R-113
Gasket, metal
37
R-321
Serrated lockwasher (old style engine)
38, 39
R-115
Stud
29
R-324
Needle bearing
38, 39
R-116
Hex nut
35
R-324M
Crankshaft / conn rod (half coupling side)
38
R-117
Stud
R-328
Gudgeon pin
38
28, 37
28, 44
23, 28, 39
38
11/2012
PAGE
63
11/2012
PARTS INDEX
PART #
DESCRIPTION
R-329
Circlip
R-331
Piston ring, 0.078"
PAGE
PART #
DESCRIPTION
PAGE
38
R-526
Washer - friction
30
38
R-528
Pawl assembly
30
R-331-0
Oversized piston ring 0.078"
38, 39
R-529
Rewind starter
30
R-331-0-1
Oversized L-type piston ring
38, 39
R-530
Housing - starter
30
R-331-1
L-type piston ring
38
R-531
Retainer - spring
30
R-332
Piston with rings
38
R-532
Cover
30
R-332-0
Oversized piston (includes rings)
38, 39
R-533
Guide - starter rope
30
R-333
Ball bearing 0.788" ID
35, 38, 39
R-544
Buffer - rubber
30
R-334
Spacer
38, 39
R-601
Pulley - manual starter rope
35
R-341
Crankshaft / conn. rod sub-assembly
38
R-602
Stud
35
R-341M
Crankshaft / conn. rod (half flywheel side)
38
R-603
Fan
35
R-342
Oil seal 0.983"
37, 38, 39
R-611
Lockwasher
36
R-343
Ball bearing 0.983" ID
38, 39
R-628
Cable condenser
36
R-344
Shim 0.004" (flywheel side)
38, 39
R-629
Spark plug 18 mm
14, 20, 36
R-345
38, 39
R-630
Cable - spark plug
36
R-346
38, 39
R-633-T
Stop switch kit
36
R-347
38, 39
R-634
Cable stop switch
36
R-348
Crankshaft / conn. rod assembly kit
38
R-636
Grommet
36
R-402
Stud
28, 29
R-637
Flat washer
36
R-408
Mach. screw
29
R-638
Mach. screw
36
R-409
Clamp - ignition cable
29
R-650
Protector - spark plug
R-411P
Fan cowl with studs
29
R-653
Gasket
35
R-413
Cover for spark plug
29
R-654
Cap
36
R-414
Mach. screw hex cap
29
R-655
Mach. screw
36
R-418
Shield - fan
29
R-656
Armature plate complete
36
R-501
Handle - starter rope
30
R-661
Coil
36
R-502
Rope - starter
30
R-662
Condenser
36
R-504
Aluminium sheave
30
R-664
Point with cable condenser
36
R-505
Lock pin
30
R-665
Mach. screw
36
R-506
Spring - rewind
30
R-667N-E
Flywheel/magneto assembly
35
R-509
Plug - rubber
30
R-706
Body quick-connect male
43
R-510
Flat "D" washer
30
R-709
Elbow
43
R-516
Spring - friction
30
R-712
Handle quick connect, female
43
R-517
Flat washer
30
R-732
Connector SAE male
43
R-518
Circlip
R-521
Lockwasher
R-522
14, 20, 36
30
R-774
Mach. screw
28
29, 30, 35, 37
R-790
Carburetor shroud with decal
28
Mach. screw hex cap
30
R-791
Lockwasher
R-523
Lockwasher
30
R-792
Throttle control assembly
28
R-524
Mach. screw
30
R-793
Mach. screw hex cap, Nylock
28
28, 35
64
PARTS INDEX
PART #
DESCRIPTION
PART #
DESCRIPTION
PAGE
R-794
Cover for air filter
28
R-1014
Mach. screw with lockwasher
25
R-798
Fuel line, plastic
43
R-1015
Fuel strainer screen
25
R-799
Bracket
28, 37
R-1016
Fuel strainer cover gasket
25
R-900
Maintenance tool kit for pump
19
R-1017
Fuel strainer cover
25
R-901
Screwdriver, 102 mm (4") sq. handle
19
R-1018
Mach. screw
25
R-902
Screwdriver, 51 mm (2")
19
R-1019
Idle mixture screw
25
R-903
Feeler gauge - spark plug & breaker point
19
R-1020
Mixture screw spring
25
R-904
Wrench - spark plug
R-904L
Wrench for lock nut/spark plug
R-905
19
R-1021
Flat washer, brass
25
41, 43
R-1022
Idle speed screw O-ring
25
Handle - rod
19
R-1023
Idle speed screw
25
R-906M
Wrench - box and open end 10 mm
19
R-1024
Idle speed screw spring
25
R-908
Wrench - open end 5 & 8 mm (ignition)
19
R-1025N
Inlet control lever
25
R-909
Key - Alien 2.4 mm (3/32")
18, 35
R-1029
Inlet tension spring
25
R-910
Wrench - open end 1/2 & 9/16
19
R-1030
High speed mixture screw
25
R-911M
Wrench - box and open end 13 mm
19
R-1034
Nozzle check valve
25
R-926
Socket wrench 14 mm (9/16)
35
R-1035
Throttle shaft and lever
25
R-927
Puller - magneto
35, 37
R-1036
Throttle shaft clip
25
R-928
Cap - shaft protector
35, 37, 38
R-1037
Lockwasher
25
R-929
Flywheel holding tool
35, 37
R-1038
Mach. screw
25
R-930
Puller - crankshaft bearing R-313
35
R-1039
Throttle shaft return spring
25
R-932
Puller - collar coupling
35, 37
R-1040
Throttle shutter
25
R-933
Oil seal - pressing tool
35, 38, 39
R-1041
Mach. screw with lockwasher
25
R-938
Puller - crankshaft bearing Ft-333
35, 38
R-1044
Lock plate
28
R-952
Service toot kit
35
R-1045
Body
25
R-953
Crankshaft jack
35, 39
R-1046N
Inlet needle and seat
25
R-954-14
Gauge - timing
35, 59
R-1047
Inlet seat gasket
25
R-955
Air filter element - foam & screen
28
R-1050
Repair parts kit
25
R-1001
Body channel welch plug
25
R-1101
Throttle link lever assembly
25
R-1002
Choke friction pin
25
R-1102
Link for throttle
28
R-1003
Choke friction spring
25
R-1107
Throttle lever sub-assembly
28
R-1004
Choke shaft and lever
25
R-1110
Hex nut
25
R-1005
Choke shutter
25
R-1111
Bolt
25
R-1008
Diaphragm gasket
25
R-1113
Gasket - carburetor
R-1009
Diaphragm
25
R-1114
Quick connect fuel line assy
R-1010
Diaphragm cover
25
R-1115
Carburetor (45 parts)
25
R-1011
Fuel pump gasket
25
RA-108
Mach. screw hex cap
37, 44
R-1012
Fuel pump diaphragm
25
TY-1811
Hex nut
R-1013
Fuel pump body
25
25, 28
43
29
11/2012
PAGE
11/2012
NOTES
65
NOTES
11/2012
66
67
WARRANTY
A. Warranty on Products Distributed by Wildfire
Wildfire makes no warranty, express or implied, with respect to any product distributed by it and manufactured by third-party manufacturers. You,
the purchaser, can only rely upon such warranties, if any, that are made by their respective manufacturers and subject the limitations that may be
contained in such warranties according to the respective terms thereof. Wildfire hereby assigns, as applicable, any such manufacturer warranty to
you as the purchaser, if assignable. However, Wildfire disclaims all other warranties or conditions for items whether express, oral, implied or
otherwise, as to any matter whatsoever, including but not limited to, implied warranties or conditions of merchantable quality or fitness for a
particular purpose and those arising by statute or otherwise in law or form a course of dealing usage of trade.
B. Warranty on Products Manufactured by or for Wildfire
Wildfire offers a limited warranty as described fully below. Among other things, it also specifically disclaims liability for:
Failure of the product if it is used for other than its intended purpose.
Changes or modifications not expressly approved by Wildfire.
Unreasonable use, supplemental damage, or damage to the product not resulting from defects in material or workmanship.
Any personal injury, damages of any kind resulting from misuse, improper installation, negligence, repair or alteration of the product.
No Consequential Damages
Some states and provinces do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations may not apply
to you. This statutory warranty gives you specific legal rights, and you may have other rights, which vary from state to state or province to province.
Wildfire offers a limited guarantee of all products manufactured by Wildfire to be free of defects in material and/or workmanship for a period of
one (1) year from date of invoice subject to use of such products strictly according to instructions. Any product manufactured by or for us believed
by you to contain a defect must be returned to Wildfire for examination and evaluation. You are responsible for payment of transportation charges.
If after inspection by us or an expert appointed by us the product is in fact found to be defective, Wildfire will repair or replace the defective
product and reimburse the original buyer for transportation charges to and from our warehouse.
Limitation of Liability
THE WARRANTY SPECIFIED HEREIN IS LIEU OF ANY AND ALL OTHER WARRANTIES, EXPRESSED, OR IMPLIED.
Wildfire hereby expressly disclaims any express or implied warranties of merchantability or of fitness for any particular purpose.
Wildfires liability on any claim of any kind, including negligence, for any damage or loss including but not limited to personal injury or
consequential damage arising out of, connected with or resulting from this contract, or from the manufacture, lease, sales, delivery, resale, return,
repair, maintenance, handling or use of any product covered by or furnished under this sale, shall in no case exceed the purchase price. Wildfire shall
not be liable for any penalty or for any special, indirect or consequential damages, including, but not limited to, any economic loss, loss of revenue
or loss of opportunity.
11/2012
The foregoing warranty is in lieu of all other warranties, express or implied, including but not limited to, any implied warranties of merchantability
or fitness for a particular purpose. Your exclusive remedy with respect to any and all losses or damages resulting from any cause whatsoever, including
our negligence, shall be repair or replacement as specified above. We shall in no event be liable for any consequential or incidental damages of any
nature, including without limitation, damages for personal injury or damages to property, and however occasioned, whether alleged as resulting
from breach of warranty or contract by us or our negligence or otherwise.
Tech-notes, part lists and other documents

can be found on our web site at
www.wildfire-env.com
Wildfire Environmental USA Inc.
16311 NE Cameron BIvd
Portland, OR
USA 97230
Tel.: (800) 4265207
(503) 257-7900
Fax: (503) 257-7979
950 Riverside Parkway, Suite 50

West Sacramento, CA
USA 95605
Tel.: (800) 426-5207
(916) 372-9004
Fax: (916) 372-9006
Wildfire Environmental Inc.

1100, rue Norman street, Suite 200
Lachine, QC
Canada H8S 1A6
Tel.: (800) 426-5207
(514) 637-5572
Fax: (514) 637-3985
E-mail: info@wildfire-env.com
Distributed by:
7965 Venture Place, Unit #3

Chilliwack, BC
Canada V2R 0K2
Tel.: (800) 426-5207
(604) 392-2240
Fax: (604) 392-2241
17426 - 106A Avenue

Edmonton, AB
Canada T5S 1E6
Tel.: (800) 426-5207
(780) 484-3705
Fax: (780) 484-5115

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Mark-3 Service Manual

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MARK-3

Portable 4-Stage Fire Pump

MARK-3 Service Manual

Digital Overspeed Switch

Electronic Ignition Module

Fuel Supply Hose Connect

MARK-3 Service Manual

Major Overhaul Service

ENGINE OVERHAUL SERVICE PROCEDURE

DISASSEMBLY PROCEDURE FOR ENGINE

REASSEMBLY SERVICE FOR ENGINE

DISASSEMBLY PROCEDURE FOR PUMP END

ASSEMBLY PROCEDURE FOR PUMP END

QUICK-CONNECT FUEL LINE

NOISE REDUCTION MUFFLER

PUMP OPERATION AND LUBRICATION

PUMP TEST KIT

CLEARANCE DATA AND LIMITS

SOLID STREAM NOZZLES

DIGITAL OVERSPEED SWITCH (DOS)

MAXIMUM PERFORMANCE VALUES

METER HEAD OF WATER AND

SERVICING SPARK PLUG

UPGRADED SPARK PLUG CAP

ELECTRONIC IGNITION UNIT

ELECTRONIC IGNITION, CONVERSION

ELECTRONIC IGNITION MODULE SETTINGS

DECOMPRESSION SWITCH R-233DS

CARBURETOR TROUBLESHOOTING CHART

AIR FILTER & CYLINDER ASSEMBLY

THE REWIND STARTER

ELECTRONIC IGNITION, INSTALLATION

MECHANICAL CUT-OUT SWITCH

STOP SWITCH KIT

DOS INSTALLATION INSTRUCTIONS

MARK-3 Service Manual

Pump end only

Max. engine power

Ducati Electronic Ignition

Bosch M4AC, NGK A8

4.5 L/hr (1.2 US gal/hr)

* For MARK-3 engines that use 14 mm spark plugs we recommend:

MARK-3 Service Manual

MARK-3 Service Manual

FOR TROUBLE FREE OPERATION

DO NOT run engine at full speed until thoroughly warmed up.

1 L (0.22 IMP gal, 0.26 US gal)

24 L (5.3 IMP gal, 6.3 US gal)

6 US gals (5 IMP gal, 22.75 L)

MARK-3 Service Manual

TO START MARK-3 UNIT

TO STOP MARK-3 UNIT

MARK-3 Service Manual

THE IMPORTANCE OF FUEL / MIXTURE RATIO, AIR / FUEL

FUEL MIXTURE RATIO

RICH MIXTURE RATIO

LEAN MIXTURE RATIO

Fuel does not burn efficiently:

Possibility of piston / cylinder

Fuel burns more efficiently:

MARK-3 Service Manual

THE IMPORTANCE OF FUEL / MIXTURE RATIO, AIR / FUEL

THE IMPORTANCE OF PROPER AIR FUEL A/F RATIO

The ratio of the amount of AIR to the amount