CARBURETOR

FUEL SYSTEM
Section 3B - Carburetor
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-1 Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-10
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-2 Idle Mixture Screw Adjustment . . . . . . . . . 3B-11
Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3B-4
3B-6
Carburetor Removal . . . . . . . . . . . . . . . . . . . . .
Carburetor Disassembly . . . . . . . . . . . . . . . . . .
3B-12
3B-13
3
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-8 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-17 B
Carburetor Adjustments . . . . . . . . . . . . . . . . . . 3B-10 Carburetor Reassembly . . . . . . . . . . . . . . . . . . 3B-19
Float Level . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-10 Carburetor Installation . . . . . . . . . . . . . . . . . . . 3B-23

Specifications
Idle rpm (Out Of Gear) 900 ± 25 rpm
Idle rpm (In Forward Gear) 800 ± 25 rpm
Wide Open Throttle rpm (WOT)
Range 5500–6000
Main Jet Size #98
Pilot Jet #38
CARBURETOR Idle Jet #42
Float Height 0.47-0.63 in. (12.0-16.0 mm)

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Special Tools
1. Carburetor Scale P/N 91-36392.

2. DMT 2000 Digital Tachometer Multi-meter P/N 91-854009A1.

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Notes:

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FUEL LINES (S/N OG960499 and Below)

4 1

3
5

5
4

7 5

5
5
6 5

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FUEL LINES
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 3 HOSE
2 1 HOSE
3 1 LINKAGE
4 3 BUSHING
5 12 CABLE TIE
6 1 HOSE
7 1 HOSE
8 1 PROTECTIVE SLEEVE

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FUEL LINES (S/N OT178500 and Up)

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FUEL LINES
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 3 HOSE
2 1 HOSE
3 1 LINKAGE
4 3 BUSHING
5 12 CABLE TIE
6 1 HOSE
7 1 HOSE & SLEEVE
8 2 CONNECTOR
9 1 FITTING (45 DEGREE)
10 1 HOSE
11 1 HOSE (3-1/2 IN.)
12 3 HOSE (90MM)
13 1 CLIP
14 1 STA-STRAP
15 3 WASHER
16 3 COTTER PIN
17 1 Y-CONNECTOR

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CARBURETOR (S/N OT178499 and Below)

2
5
7
6

2
5
3

4
8
1

9
12
10 13
11

29
15 14
21
16 27
2
1
23
22
17

19 20 18
19
20 18
21
2

1
24

28
26

25

20 17
19 18

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CARBURETOR
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm
1 CARBURETOR (TOP)
1 1 CARBURETOR (CENTER)
1 CARBURETOR (BOTTOM)
2 10 SCREW
3 3 PLATE
4 3 GASKET
5 1 ENRICHENER
6 1 O RING
7 1 PLATE
8 3 JET (IDLE)
9 3 JET (SLOW)
10 3 RUBBER PLUG
11 3 JET (MAIN)
12 3 FLOAT VALVE
13 3 MAIN NOZZLE
14 3 FLOAT
15 3 FLOAT PIN
16 3 GASKET
1 FLOAT BOWL (TOP)
17
2 FLOAT BOWL (CENTER/BOTTOM)
18 12 SCREW
19 3 DRAIN SCREW
20 3 WASHER
2 SYNCHRONIZATION SCREW (TOP/CENTER)
21
1 STOP SCREW (BOTTOM)
22 2 SPRING (TOP/CENTER)
23 2 SPRING (TOP/CENTER)
24 1 SPRING (BOTTOM)
25 1 SPRING
26 1 PLUNGER
27 3 RUBBER, BELLOWS
28 3 PLUNGER RETAINING SCREW
29 3 PLUNGER ROD

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CARBURETOR (S/N OT178500 and Up)

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CARBURETOR
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm
1 CARBURETOR (TOP)
1 1 CARBURETOR (CENTER)
1 CARBURETOR (BOTTOM)
2 16 SCREW
3 3 PLATE
4 3 GASKET
5 1 ENRICHENER
6 1 O RING
7 1 PLATE
8 3 CAP
9 3 IDLE MIXTURE SCREW
10 3 O-RING
11 3 SPRING
12 3 JET (SLOW)
13 3 O-RING
14 3 PLUG
15 3 JET (MAIN)
16 3 MAIN NOZZLE
17 3 FLOAT VALVE
18 3 FLOAT
19 3 FLOAT PIN
20 3 SCREW
21 3 GASKET
1 FLOAT BOWL (TOP)
22
2 FLOAT BOWL (CENTER/BOTTOM)
23 12 SCREW
24 3 DRAIN SCREW
25 3 WASHER
26 2 SYNCHRONIZATION SCREW (TOP/CENTER)
27 2 SPRING (TOP/CENTER)
28 2 SPRING (TOP/CENTER)
29 1 STOP SCREW (BOTTOM)
30 1 SPRING (BOTTOM)
31 1 SPRING
32 1 PLUNGER
33 3 PLUNGER RETAINING SCREW
34 3 RUBBER, BELLOWS
35 3 PLUNGER ROD

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INTAKE

16

15

3
2
8 10
9
11 14

7
10
13
12
5

12
4
6

12

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INTAKE
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 6 SCREW
2 1 AIR INTAKE
3 3 O RING
4 1 PLATE
1 ISOLATOR (40)
5
1 ISOLATOR (30)
6 2 PLUG
7 1 SOUND ATTENUATOR
8 2 SCREW (M6 x 20)
9 2 BUSHING
10 6 STA-STRAP
11 3 SEAL
12 9 O RING
13 2 DOWEL PIN
14 6 SCREW (M6 x 25)
15 1 BREATHER HOSE
16 1 STA-STRAP

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Carburetor Adjustments
Float Level
1. With carburetor turned upside down and carb scale seated on inner edge, check float
level from top of float to float bowl flange as shown.

Float Height
0.47-0.63 in. (12.0-16.0 mm)

Idle Speed
NOTE: Outboard should be completely warmed up for the idle speed adjustment.
NOTE: Turning the idle speed adjustment screw clockwise will increase idle speed. Turn-
ing the adjustment screw counterclockwise will decrease idle speed.
1. With the outboard in forward gear adjust idle speed screw to obtain the specified idle
speed.

a - Idle Speed Screw

b - Phillips Head Screwdriver

Idle Speed (Forward Gear)

800 ± 25 RPM

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Idle Mixture Screw Adjustment

NOTE: Access to idle mixture screws can only be made by removing the sealing plug. Dril-
ling a small hole in the center of the plug and using an awl to pry out the plug must be done
with extreme caution. The sealing plug is very thin and the idle mixture screw is located di-
rectly behind the plug. It is recommended that additional idle mixture screws be ordered for
stock should the original mixture screw be damaged during drilling or the removal process.
Idle mixture screw adjustment is strictly regulated by the Environmental Protection Agency.
However, if the carburetor is overhauled, the EPA allows the adjustment of the mixture
screws. Each idle mixture screw (1 per carburetor) is located behind a sealing plug. The
sealing plug can be removed by carefully drilling a small hole in the center of the plug and
prying the plug out with an awl. After mixture screws have been adjusted, a new sealing plug
MUST BE installed over each mixture screw.

a b c

58474 58473

59245

a - Plug
b - Idle Mixture Screw (behind plug)
c - Install new plug and seat flush with casting after adjusting idle mixture screw
Idle Mixture Screw – Turns Out
1-5/8 ± 1/2

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Carburetor Removal
1. Disconnect auto enrichener wires, breather hose, and fuel supply lines.

b
a

c
a - Auto Enrichener Wires (Yellow)
b - Breather Hose
c - Fuel Supply Line

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2. Remove intake and carburetor mounting screws.

a - Intake Mounting Screw (3)-M6x20

b - Carburetor Mounting Screw (6)

Carburetor Disassembly
Carburetors Not Equipped With Bowl Vent Hoses
1. Remove sound attenuator, air intake and plate from carburetor assembly.

b
a

d
c

a - Sound Attenuator
b - Screw (6)
c - Air Intake
d - Carburetor Assembly
e - Plate
f - Isolator

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2. Remove auto enrichener.

c
a

b
d

a - Auto Enrichener
b - Plate
c - Screw
d - O-Ring

3. Remove fuel lines and unsnap linkage.

b b

b
b

a - Linkage
b - Fuel Lines

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Carburetors Equipped With Bowl Vent Hoses

1. Remove sound attenuator and plate from carburetor assembly.

a - Sound Attenuator
b - Carburetor Assembly
c - Plate
d - Isolator
2. Remove auto enrichener.

c
a

b
d

59258

a - Auto Enrichener
b - Plate
c - Screw
d - O-Ring

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1. Remove fuel hoses and disconnect the throttle linkage.

a
c
e
e
c

c
b
d

d
d
59260
59259

a - Linkage
b - Fuel Lines
c - Enrichener/Balance Hoses
d - Bowl Vent Hoses
e - Enrichener Vent Hose

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 CARBURETOR

DISASSEMBLY CONTINUED (ALL MODELS)

2. Remove float bowl.
3. Remove plunger, spring, and gasket.

f
e
c
d
b

a
a - Screws (4)
b - Float Bowl
c - Plunger
d - Spring
e - Gasket
f - Retaining Screw

4. Remove float, plug, nozzles and jets.

NOTE: Earlier models are likely equipped with the old style float..

a g
c
b e h
f

a - Screw e - Plug
b - Float Pin f - Slow Jet
c - Old Style Float g - Main Jet
d - New Style Float h - Main Nozzle

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5. Remove cover and gasket.

a - Screws (3)
b - Cover
c - Gasket
d - Idle jet

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Inspection
1. Inspect needle and piston valve. Replace if worn or damaged.
2. Measure auto enrichener resistance. Replace if out of specification.

Auto Enrichener Resistance

15-25 Ω @ 68°F (20°C)

3. Perform piston valve height test below.

Piston Valve Height Test:
a. Measure piston valve height
b. Connect to 12 V battery
c. Wait several minutes
d. Measure piston valve height
4. Replace auto enrichener if no change was observed.

a - Piston Valve Height Measurement

5. Inspect carburetor body, replace if cracked or damaged.

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6. Inspect float, replace if cracked or damaged.

b
a

a - Old Style Float

b - New Style Float
CAUTION
Do not use steel wire for cleaning the jets as this may enlarge the jet diameters and
seriously affect performance. Use a petroleum based solvent for cleaning and blow
out all passages with compressed air.
7. Inspect idle mixture screw (if equipped). Replace if bent or damaged.

53673

8. Inspect main jet, idle jet, slow jet and main nozzle. Clean if they are contaminated.

9. Inspect needle valve, replace if end is worn or grooved.

28375

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Carburetor Reassembly
1. Install idle jet (if equipped), gasket, and cover.

a - Screws (3)
b - Cover
c - Gasket
d - Idle jet

2. Install jets, nozzles, plug and float.

NOTE: Earlier models are likely equipped with the old style float..

a
h
c
b f i
b
e g
c

a - Screw f - Plug
b - Float Pin g - Slow Jet
c - Old Style Float h - Main Jet
d - New Style Float i - Main Nozzle
e - Needle Valve

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3. Install plunger and spring.

4. Install gasket bowl and float.

f
e
c
d
b

a
a - Screws (4) d - Spring
b - Float Bowl e - Gasket
c - Plunger f - Retaining Screw

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Carburetors Not Equipped With Bowl Vent Hoses

5. Install fuel hoses and throttle linkage. Secure hoses with cable ties where shown.

b
b

b
b

a - Linkage
b - Fuel Hoses

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Carburetors Equipped With Bowl Vent Hoses

1. Install hoses and throttle linkage. Secure hoses with cable ties where shown.

a
c
e
e
c

c
b
d

d
d
59260
59259

a - Throttle Linkage
b - Fuel Hoses
c - Enrichener/Balance Hoses
d - Bowl Vent Hoses
e - Enrichener Vent Hose

2. Install auto enrichener.

c
a

b
d

a - Auto Enrichener
b - Plate
c - Screw
d - O-Ring

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3. Install air intake and plate onto carburetor assembly.

b
a

d
c

a - Sound Attenuator
b - Screw (6)
c - Air Intake
d - Carburetor Assembly
e - Plate
f - Isolator

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Carburetor Installation
1. Install intake and carburetor mounting screws.

a - Intake Mounting Screw (3)-M6 x 20

b - Carburetor Mounting Screw (6)

Carburetor Mounting Screw Torque

70 lb. in. (8 N·m)

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2. Connect auto enrichener wires, breather hose, fuel supply hose, and bowl vent hoses.

b a

d e

c
a - Auto Enrichener Wires (Yellow)
b - Breather Hose
c - Fuel Supply Hose
d - Bowl Vent Hose (if equipped)
e - Through Hole in Adaptor Plate

NOTE: Carburetor synchronization is required after rebuilding carburetors. Refer to section

2C, Timing/Synchronizing/Adjusting.

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