Control valve assembly of a carburetor and method of assembly

1. In a combustion engine carburetor having a body with a fuel-and-air mixing passage extending therethrough and a control valve assembly constructed and arranged in part in the fuel-and-air mixing passage for control of flow through the fuel-and-air mixing passage and to a combustion engine, the control valve assembly comprising:

a shaft extending transversely across the fuel-and-air mixture passage and supported rotatably by the body about an axis;

a first end portion of the shaft projecting outward from the body;

an opposite second end portion of the shaft projecting outward from the body;

an axial retention feature having a radially enlarged cap formed unitarily as one piece to the first end portion; and

a disengageable coupler engaged to the second end portion.

2. The control valve assembly set forth in claim 1 further comprising the coupler having a collar disposed about the second end portion and at least one flex arm projecting from the collar for axial retention of the collar to the shaft.

3. The control valve assembly set forth in claim 2 further comprising at least one radially projecting control lever engaged removably to at least one of the first end portion or the second end portion.

4. The control valve assembly set forth in claim 3 wherein the collar of the coupler is unitarily formed to a control lever of the at least one control levers.

5. The control valve assembly set forth in claim 3 further comprising a rotation restriction feature carried between the at least one control lever and the respective at least one of the first end portion or the second end portion.

6. The control valve assembly set forth in claim 4 further comprising the control lever of the at least one control levers has a rotation restriction feature carried between the control lever and the second end portion.

7. The control valve assembly set forth in claim 5 further comprising the rotation restriction feature having at least one flat side carried by the respective at least one of the first end portion or the second end portion facing radially outward and extending axially, and at least one flat surface carried by the at least one control lever, and wherein each one of the at least one flat surfaces are aligned circumferentially to and disposed against each respective one of the at least one flat sides.

8. The control valve assembly set forth in claim 2 wherein the at least one flex arm projects axially.

9. The control valve assembly set forth in claim 6 wherein the collar has a non-circular hole for receipt of the shaft.

10. The control valve assembly set forth in claim 9 wherein the control lever of the at least one control lever is a cam member having a follower arm projecting radially outward from the collar independent from the at least one flex arm.

11. The control valve assembly set forth in claim 10 further comprising the coupler having a groove opened radially outward from the first end portion and a tang projecting radially inward from a distal end of the at least one flex arm for snap receipt into the groove.

12. The control valve assembly set forth in claim 6 wherein the control valve assembly has a throttle valve having the shaft and the control lever.

13. The control valve assembly set forth in claim 12 wherein the control lever is a fast idle cam member having a follower arm projecting radially outward from the collar for camming contact with a second control lever of the at least one control levers associated with a choke valve having a second rotating shaft supported by the body of the carburetor.

14. The control valve assembly set forth in claim 13 further comprising a throttle lever being one of the at least one control levers attached to the second end portion of the shaft of the throttle valve and disposed axially between the unitary cap and the body.

15. The control valve assembly set forth in claim 14 further comprising a spring wound about the shaft, disposed axially between the throttle lever and the cam member, and engaged between the throttle lever and the body for yieldably biasing the throttle lever to an idle position.

16. A combustion engine carburetor comprising:

a body;

a fuel-and-air mixing passage through the body;

a through-bore communicating through the body and extending across the fuel-and-air mixing passage; and

a valve for controlling flow through the fuel-and-air mixing passage, the valve having:

a shaft journaled for rotation to the body about an axis and in the through-bore, the shaft having leading and trailing end portions projecting outward from the body in opposite directions;

a cross sectional area of the leading end portion orientated perpendicular to the axis being less than a cross sectional area of the trailing end portion orientated perpendicular to the axis,

a control lever engaged to the leading end portion,

a rotation restriction feature carried between the leading end portion and the control lever, and

axial retention feature carried at least in part between the leading end portion and the control lever.

17. The combustion engine carburetor set forth in claim 16 wherein the valve is a throttle valve.

18. The combustion engine carburetor set forth in claim 17 wherein the control lever is a member being in rotational contact with a choke valve.

19. The combustion engine carburetor set forth in claim 18 further comprising a coupler of the axial retention feature formed at least in part unitarily to the member and snap fitting removably to the leading end portion.

20. The combustion engine carburetor set forth in claim 19 further comprising a mid section of the shaft located in the through-bore, extending between the leading and trailing end portions and having a cross sectional area disposed perpendicular to the axis that is larger than the cross sectional area of the leading end portion and smaller than the cross sectional area of the trailing end portion, and wherein the through-bore is closely fitted to the mid section.

21. The combustion engine carburetor set forth in claim 20 further comprising a throttle lever engaged to the trailing end portion.

22. The combustion engine carburetor set forth in claim 21 further comprising:

the axial retention feature having a radially enlarged cap formed unitarily to the trailing end portion of the shaft of the throttle valve as one piece;

the throttle lever being removable from the shaft of the throttle valve and located axially between the cap and the body; and

a rotational retention feature carried between the trailing end portion and the throttle lever to prevent rotation of the throttle lever with respect to the shaft.

23. The combustion engine carburetor set forth in claim 22 further comprising a plate of the throttle valve disposed pivotally in the fuel-and-air mixing passage and engaged to the mid-section of the shaft.

24. The combustion engine carburetor set forth in claim 23 further comprising:

a slot communicating laterally through and extending axially with respect to the mid-section of the shaft and located in the fuel-and-air mixing passage; and

the plate press fitted into the slot.

25. The combustion engine carburetor set forth in claim 22 further comprising a spring wound about the shaft and disposed axially between the throttle lever and the body for yieldably biasing the throttle valve into an idle position.

26. The combustion engine carburetor set forth in claim 22 further comprising:

the choke valve having a choke shaft journaled to the body through a through-bore and having a first end portion projecting outward from the body, an opposite second end portion projecting outward from the body, an enlarged end cap projecting radially outward from and formed unitarily to the first end portion so that the choke shaft and the end cap are one piece; and

the choke valve having a choke lever engaged to the first end portion of the choke shaft and disposed between the enlarged end cap and the body wherein the first end portion extends through the choke lever and is circumferentially engaged to the choke lever to prevent rotation of the choke lever with respect to the choke shaft and is axially retained by the end cap.

27. The combustion engine carburetor set forth in claim 26 further comprising a choke spring wound about the first end portion and disposed axially between and engaged to the choke lever and the body.

28. The combustion engine carburetor set forth in claim 27 further comprising a retaining clip snap fitted into a continuous groove carried by the second end portion for preventing the choke shaft from moving out of the body.

29. The combustion engine carburetor set forth in claim 19 further comprising at least one flex arm of the coupler having a tang projecting radially inward from a distal end of the at least one flex arm and snap fitted into a groove of the coupler carried by the leading end portion of the throttle shaft.

30. The combustion engine carburetor set forth in claim 29 further comprising:

the at least one flex arm being two diametrically opposed flex arms projecting axially outward with respect to the body; and

the member having two rigid axially projecting shanks orientated circumferentially between the two flex arms.

31. The combustion engine carburetor set forth in claim 30 further comprising two diametrically opposed flat surfaces of the rotation restriction feature carried by the two shanks and confronting respective flat sides of the rotation restriction feature carried by the leading end portion.

32. A method of assembling in a carburetor having a body with a fuel-and-air mixing passage in the body, a control valve assembly comprising the steps of:

unitarily forming as one piece a shaft having an enlarged end cap at a trailing end portion;

inserting an opposite leading end portion of the shaft through a control lever;

circumferentially aligning the control lever to the trailing end portion and axially inside of the end cap so that the control lever does not rotate with respect to the shaft;

axially abutting the control lever to the enlarged end cap;

inserting the leading end portion of the shaft through a coiled spring;

inserting the leading end portion into the carburetor body, through the fuel-and-air mixing passage in the body and until the leading end portion projects outward from the body; and

engaging opposite ends of the coiled spring between the control lever and the body for rotatably biasing the shaft.

33. The method of assembling the carburetor control valve assembly set forth in claim 32 comprising the further steps of:

circumferentially aligning a cam member to the leading end portion;

sliding the cam member axially onto the leading end portion; and

snap fitting a coupler carried at least in part by the cam member to the leading end portion for axial retention.

34. The method of assembling the carburetor control valve assembly set forth in claim 33 comprising the further steps of:

resiliently flexing at least one flex arm of the coupler radially outward as the cam member slides axially onto the leading end portion; and

snap fitting a tang of the at least one flex arm radially into a recess in the leading end portion as the cam member axially aligns to the leading end portion and the at least one flex arm radially moves back into a natural state.