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2023 ZAMA service manual

hero_n6600

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HI, everyone. Does anyone has the latest 2023 ZAMA service manual? here is link on youtube channel--https://www.youtube.com/watch?v=Tt0aM4AB37Y
Has problem with my old FS94 RC2 rotary ZAMA carb. Thank you.
 

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HI, everyone. Does anyone has the latest 2023 ZAMA service manual? here is link on youtube channel--https://www.youtube.com/watch?v=Tt0aM4AB37Y
Has problem with my old FS94 RC2 rotary ZAMA carb. Thank you.
From what I read - only paper copies no pdf. So someone would have to scan it.
 

stihl #1

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There are 2 versions used, one with an attached primer and one with a remote primer. I wrote this eval procedure when I was working at STIHL, back in 2020. Hope it helps. You will need some special tools to do it the way I wrote it, since it was for dealers who were supposed to have these tools on site.
 

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hero_n6600

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Thank you for your useful troubleshooting PDF and upon inspect my RC2 carburettor. I found:

1: when follow your step outlined in page 16, step 4, by pump bulb 3-4 times, it shows negative pressure. Upon release the bulb, it has a very slow gradual decrease pressure as well. I just want clarify yours saying “ hold for at least a full second”, mine was drop by 1 every 2-3 seconds, is it normal?

2: when inspect white plastic fuel discharge tube, there is top port, but I also found a side port in the middle section of plastic fuel. It is hard to take photo’s I just draw a red circle from your PDF for demonstration. So is there a side port from your memory? Please see photo uploaded.

3: I have successfully fine tuning on non rotary type carburettor before, such as L and H screw next to each other. Traditionally, the initially setting on L screw has to be 1 anti-clockwise turn after seated to prevent too lean while idling. On the other hand, however, on my RC2, I have to screw all the way in for LA screw and anti-clockwise 1/8 turn from seated on L screw to make it idle at 2800RPM, if I make it anti-clockwise further, engine will die. My question is: will it too lean for the engine as L screw is only 1/8 turn from seated. I have not done much rotaty type carburettor before

 

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hero_n6600

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There are 2 versions used, one with an attached primer and one with a remote primer. I wrote this eval procedure when I was working at STIHL, back in 2020. Hope it helps. You will need some special tools to do it the way I wrote it, since it was for dealers who were supposed to have these tools on site.
Thank you for your useful troubleshooting PDF and upon inspect my RC2 carburettor. I found:

1: when follow your step outlined in page 16, step 4, by pump bulb 3-4 times, it shows negative pressure. Upon release the bulb, it has a very slow gradual decrease pressure as well. I just want clarify yours saying “ hold for at least a full second”, mine was drop by 1 every 2-3 seconds, is it normal?

2: when inspect white plastic fuel discharge tube, there is top port, but I also found a side port in the middle section of plastic fuel. It is hard to take photo’s I just draw a red circle from your PDF for demonstration. So is there a side port from your memory? Please see photo uploaded.

3: I have successfully fine tuning on non rotary type carburettor before, such as L and H screw next to each other. Traditionally, the initially setting on L screw has to be 1 anti-clockwise turn after seated to prevent too lean while idling. On the other hand, however, on my RC2, I have to screw all the way in for LA screw and anti-clockwise 1/8 turn from seated on L screw to make it idle at 2800RPM, if I make it anti-clockwise further on LA or L screw, engine will die. My question is: will it too lean for the engine as L screw is only 1/8 turn from seated. I have not done much rotary type carburettor before.
 

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stihl #1

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I never noticed the small port but best guess is that it is supposed to be there. When you pull the negative pressure with the primer bulb, after 3-4 pumps, stop and say one-one-thousand and the needle should hold at least that long. If it holds longer great, but if it starts bleeding off before you say one-one-thousand then you have a slow internal leak, probably the low speed check valve which will not effect running, just how well it primes. If this engine has a lot of run time it may not be the carb, it could be a leaking seal on the crank, which will make it hard to tune, and maybe you get it to tune today but tomorrow it runs crappy again, or just runs erratic. I forgot I have a worksheet that goes with the tutorial, see attached. Do you know how to do a pressure vac test on the crankcase? The other thing that can cause an issue is how you adjust the carb.
Screenshot 2025-11-19 183957.jpg
So for the first carb shown with the integral primer, says on the side of the carb 4149/02, set the H screw, the one on the top of the rotary valve, at 1 1/2 out from lightly seated, and the L screw at 2 1/2. If you have the carb that has S243 on it and the remote primer, set the H at 1 1/4 and the L at 1 1/2. The engine should run here. If it doesn't there is something wrong in the engine or the carb is just no good. I have had carbs pass all the tests and just not work, especially if they are old and have been sitting with fuel in them. If it runs warm it up and set the idle with a tach at 3300 RPM. It must idle smoothly, not erratic. Then do lean drop off tuning. So at 3300 rpm slowly turn the L screw in, leaning the mixture and then out making it richer until you find the highest RPM. You should end up a few hundred revs higher than 3300, so reset the idle screw back to 3300. Now go back and forth with the L screw again and see if the lean drop off RPM goes any higher, and if so go back to 3300 again with the idle screw. If the carb is good and the engine has no problems this process may take 2 or 3 tries until you have the L screw at lean drop off, where if you turn in at all the RPM goes down, with the idle screw at 3300. Now back out the L screw to lower the RPM by enriching the mixture, until you are at 2800 RPM which is the target idle speed we want. This will give you good throttle response and good drop off back to idle with no stalling. This process is how you know the carb is working properly. If it is not sensitive to this tuning then replace it, again assuming the engine doesn't have any crankcase leaks or other problems. Once this is done with a trimmer head on it, and the line at the right length hold it wide open and set the H screw for around 9800 RPM if you can. If it only will get to 9600 or 9700 that's OK but don't set it any higher if it will go higher. This gives you good power and fuel cooling, where a leaner setting would actually cause it to run hotter and have less power under load.
I know I am getting deep here but you asked and I assume you are interested in learning. When I evaluate a unit I do a full engine check. I need to know what is OK just as well as I need to know any faults that may be present. I learned this the hard way more than once when I jacked around with a carb and the engine had a scored piston, but still had good compression, or some other fault that had me chasing the carb when it was actually OK.
 

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EFSM

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Let me see if I can avoid the TL;DR disease.
If this is a high hour machine it might have a worn low mix needle. I have seen that one time before in the thousands of trimmers I have worked on and it was this model of carburetor on this model of trimmer. The lower part of the needle, which fits into the plastic fuel jet, was worn on the one side and allowed too much fuel through. You had to turn the idle mix all the way lean and turn up the throttle stop the whole way to keep it idling.

From your description this is exactly what is happening.
 

hero_n6600

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I never noticed the small port but best guess is that it is supposed to be there. When you pull the negative pressure with the primer bulb, after 3-4 pumps, stop and say one-one-thousand and the needle should hold at least that long. If it holds longer great, but if it starts bleeding off before you say one-one-thousand then you have a slow internal leak, probably the low speed check valve which will not effect running, just how well it primes. If this engine has a lot of run time it may not be the carb, it could be a leaking seal on the crank, which will make it hard to tune, and maybe you get it to tune today but tomorrow it runs crappy again, or just runs erratic. I forgot I have a worksheet that goes with the tutorial, see attached. Do you know how to do a pressure vac test on the crankcase? The other thing that can cause an issue is how you adjust the carb.
View attachment 475269
So for the first carb shown with the integral primer, says on the side of the carb 4149/02, set the H screw, the one on the top of the rotary valve, at 1 1/2 out from lightly seated, and the L screw at 2 1/2. If you have the carb that has S243 on it and the remote primer, set the H at 1 1/4 and the L at 1 1/2. The engine should run here. If it doesn't there is something wrong in the engine or the carb is just no good. I have had carbs pass all the tests and just not work, especially if they are old and have been sitting with fuel in them. If it runs warm it up and set the idle with a tach at 3300 RPM. It must idle smoothly, not erratic. Then do lean drop off tuning. So at 3300 rpm slowly turn the L screw in, leaning the mixture and then out making it richer until you find the highest RPM. You should end up a few hundred revs higher than 3300, so reset the idle screw back to 3300. Now go back and forth with the L screw again and see if the lean drop off RPM goes any higher, and if so go back to 3300 again with the idle screw. If the carb is good and the engine has no problems this process may take 2 or 3 tries until you have the L screw at lean drop off, where if you turn in at all the RPM goes down, with the idle screw at 3300. Now back out the L screw to lower the RPM by enriching the mixture, until you are at 2800 RPM which is the target idle speed we want. This will give you good throttle response and good drop off back to idle with no stalling. This process is how you know the carb is working properly. If it is not sensitive to this tuning then replace it, again assuming the engine doesn't have any crankcase leaks or other problems. Once this is done with a trimmer head on it, and the line at the right length hold it wide open and set the H screw for around 9800 RPM if you can. If it only will get to 9600 or 9700 that's OK but don't set it any higher if it will go higher. This gives you good power and fuel cooling, where a leaner setting would actually cause it to run hotter and have less power under load.
I know I am getting deep here but you asked and I assume you are interested in learning. When I evaluate a unit I do a full engine check. I need to know what is OK just as well as I need to know any faults that may be present. I learned this the hard way more than once when I jacked around with a carb and the engine had a scored piston, but still had good compression, or some other fault that had me chasing the carb when it was actually OK.
Hi, Stihl NO1:

1: one-one-thousand, does it mean 1:1000 second?

2: For the side port in the middle of session of the plastic fuel tube, it seems normal to have a cut-out structure on this rotary carburettor, youtube videos shows that cutout structure at 4:45mins

3: Vac and pressure test was fine by following Tom’s vintage engine repair instruction:





4: As per service manual for L screw initial setting: 1.5 anticlockwise turn from seated and H screw initial setting: 1.25 anticlockwise turn from seated. Engine only start when LA screw all the way in and L screw is on fully close position to 0.25 (1/4) opening position. Thus, I was not able to a do lean drop off tuning on my FS94, but have done before on few Stihl 2 stroke engine with tachometer, video refer to your lean drop off tuning description: https://www.youtube.com/watch?v=UyngDl_2km0

5: how deep the H screw suppose to be in? I just measure with digital caliper measure from top of the screw to the top metal flash, around 1.7-1.8mm, will it be too deep or can go deeper? manual stated to be seated, I feel like can go more further to 2.0mm, but doesn't want to damage the H screw, see photo in red circle
 

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hero_n6600

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Let me see if I can avoid the TL;DR disease.
If this is a high hour machine it might have a worn low mix needle. I have seen that one time before in the thousands of trimmers I have worked on and it was this model of carburetor on this model of trimmer. The lower part of the needle, which fits into the plastic fuel jet, was worn on the one side and allowed too much fuel through. You had to turn the idle mix all the way lean and turn up the throttle stop the whole way to keep it idling.

From your description this is exactly what is happening.
Hi, EFSM, see photo of my RC2 rotary with oring on the barrel , white plastic fuel, L screw. L screw seems has minor scratch at the end, but it is metal and it is only contact with white plastic fuel tube, no idea where scratches come from.
 

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EFSM

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That is your problem. Replace that needle and you will have your adjustment working again. It is an extremely soft metal (brass alloy) instead of the stainless steel needles that Walbro uses, which never wear out.
 

hero_n6600

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That is your problem. Replace that needle and you will have your adjustment working again. It is an extremely soft metal (brass alloy) instead of the stainless steel needles that Walbro uses, which never wear out.
Ok, thanks, going to order a L screw needle
And is the thin oring fit it correctly on the barrel?
 

EFSM

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There are 2 versions used, one with an attached primer and one with a remote primer. I wrote this eval procedure when I was working at STIHL, back in 2020. Hope it helps. You will need some special tools to do it the way I wrote it, since it was for dealers who were supposed to have these tools on site.
How long did you work for Stihl?
 

stihl #1

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What I mean by one-one-thousand is to say that out load to approximate one second of elapsed time. Sorry that wasn't clear, so pull the vacuum with the bulb let one second go by and the needle should not start back to zero before the second has elapsed. It is hard to look at a stopwatch and the gauge at the same time! Anyway the point is that it if it leaks down immediately you have an internal leak, either in the primer bulb check valve or the metering chamber check valves.
Screenshot 2025-11-20 181505.jpg
EFSM is right, if that needle is not in good shape that may be the problem. I personally have never seen that because the commercial guys here in the USA use pump gas and the carbs get ruined by that (leaking check valves) way before they run long enough to wear away a needle.
EFSM, I worked at STIHL Inc. for over 18 years, retired in Jan 2021.
 
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hero_n6600

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The o-ring needs to be slid up above the rotor into a little groove if it’s like the normal Zama RB carbs
Thank you for your reply. When I initially took of the rotor found the oring was sitting on the above the rotor in the little grove, then look at the manual, though it was misplaced. Now thank you for the new insight, I just reattach new photo, does it sound correct?
 

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