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Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Throttle Assembly Replacement

Introduction

Use this guide to remove or replace the throttle assembly on a Wacker BS50-4AS REV 101 (2019) Vibrator/Rammer.

What you need

  1. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Throttle Assembly Replacement, Disconnect the spark plug wire: step 1, image 1 of 2 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Throttle Assembly Replacement, Disconnect the spark plug wire: step 1, image 2 of 2

    • Ensure the device is powered down and cool to the touch before starting your repair.

    • Firmly grip the base of the spark plug wire's connector and pull it away from the spark plug to disconnect it.

    Edit

  2. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Throttle Assembly Replacement, Remove the ground wire: step 2, image 1 of 2 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Throttle Assembly Replacement, Remove the ground wire: step 2, image 2 of 2

    • Use a 10 mm socket to remove the bolt securing the throttle assembly's ground wire.

    • Remove the ground wire.

    Edit

  3. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Throttle Assembly Replacement, Remove the power wire: step 3, image 1 of 2 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Throttle Assembly Replacement, Remove the power wire: step 3, image 2 of 2

    • Grip the throttle cable's black wire bullet connecter and pull to disconnect it from the engine.

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  4. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Throttle Assembly Replacement, De-route the wires: step 4, image 1 of 3 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Throttle Assembly Replacement, De-route the wires: step 4, image 2 of 3 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Throttle Assembly Replacement, De-route the wires: step 4, image 3 of 3

    • Grab both ends of the throttle wires and feed them out, past the metal engine guard.

    Edit

  5. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Throttle Assembly Replacement, Cut the wire cable tie: step 5, image 1 of 1

    • Use a pair of flush cutters to cut the cable tie securing the throttle wires together.

    • During reassembly, replace this cable tie.

    Edit

  7. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Throttle Assembly Replacement, Move the throttle lever: step 6, image 1 of 2 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Throttle Assembly Replacement, Move the throttle lever: step 6, image 2 of 2

    • Move the throttle lever all the way into the SLOW position, towards the front of the device, to loosen tension on the throttle cable.

    Edit

  8. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Throttle Assembly Replacement, Remove the throttle cable screw: step 7, image 1 of 2 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Throttle Assembly Replacement, Remove the throttle cable screw: step 7, image 2 of 2

    • Use a Phillips driver to remove the screw securing the throttle cable to the actuator arm on the motor.

    • You may need to use a 10 mm wrench to hold the nut in place as you remove the screw.

    Edit

  9. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Throttle Assembly Replacement, Remove the throttle assembly bolts: step 8, image 1 of 1

    • Use an 8 mm socket to remove the two bolts securing the throttle assembly to the frame.

    Edit

  10. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Throttle Assembly Replacement, Lower the throttle assembly: step 9, image 1 of 2 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Throttle Assembly Replacement, Lower the throttle assembly: step 9, image 2 of 2

    • Grip the throttle assembly from underneath and lower it down through its cutout in the frame.

    • Don't attempt to fully remove the throttle assembly yet. Let the assembly hang in place.

    Edit

  11. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Throttle Assembly Replacement, Remove the throttle cable: step 10, image 1 of 3 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Throttle Assembly Replacement, Remove the throttle cable: step 10, image 2 of 3 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Throttle Assembly Replacement, Remove the throttle cable: step 10, image 3 of 3

    • Holding the throttle assembly in place, pull the throttle cable through the hole on the throttle lever.

    • Remove the throttle cable.

    • During reassembly, be careful not to fray the throttle cable tip, or you won't be able to install the cable.

    • During reassembly, ensure the throttle cable guide shoulder is fully recessed into its section on the throttle assembly.

    Edit

  12. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Throttle Assembly Replacement, Prepare for fuel drips and spills: step 11, image 1 of 1

    • Place a rag or shop towel underneath the petcock fuel lines to prevent drips and spills from getting on the device.

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  13. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Throttle Assembly Replacement, Remove the fuel tubes: step 12, image 1 of 3 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Throttle Assembly Replacement, Remove the fuel tubes: step 12, image 2 of 3 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Throttle Assembly Replacement, Remove the fuel tubes: step 12, image 3 of 3

    • Grip one of the clear fuel tubes near where it connects to the petcock and squeeze it completely closed.

    • Pull the tube directly away from the petcock nipple to remove it.

    • This may require some force due to suction within the tubes.

    • Use a pick tool to lift one end of the tube up to break suction if needed.

    • Residual fuel in the fuel lines may leak out after the tube is removed.

    • Disconnect the second fuel tube from the petcock.

    Edit

  14. Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Throttle Assembly Replacement, Remove the throttle assembly: step 13, image 1 of 3 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Throttle Assembly Replacement, Remove the throttle assembly: step 13, image 2 of 3 Wacker 4-Stroke Rammer BS504AS REV 101 (2019) Throttle Assembly Replacement, Remove the throttle assembly: step 13, image 3 of 3

    • Thread the throttle wires out from underneath the metal engine guard.

    • Remove the throttle assembly.

    • Only the throttle assembly remains.

    Edit
Conclusion

To reassemble your device, follow these instructions in reverse order.

One other person completed this guide.

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Carsten Frauenheim

Member since: 03/10/20

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