3B

CARBURETOR

90-856159R1 AUGUST 1998 Page 3B-1

FUEL SYSTEMSection 3B – Carburetor

Table of ContentsSpecifications 3B-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools 3B-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carburetor 3B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carburetor 3B-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intake 3B-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intake 3B-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carburetor Adjustments 3B-6. . . . . . . . . . . . . . . . . . . .

Idle Speed 3B-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Linkage 3B-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Choke 3B-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carburetor Removal 3B-11. . . . . . . . . . . . . . . . . . . . . . Carburetor Disassembly 3B-13. . . . . . . . . . . . . . . . . . . Cleaning/Inspection/Repair 3B-15. . . . . . . . . . . . . . . . Carburetor Reassembly 3B-16. . . . . . . . . . . . . . . . . . .

Float Height Measurement 3B-18. . . . . . . . . . . . . . Carburetor Installation 3B-19. . . . . . . . . . . . . . . . . . . .

Electric Choke Models Installation 3B-19. . . . . . .

Specifications

CARBURETOR

Idle rpm (Out Of Gear)Idle rpm (In Forward Gear)Wide Open Throttle rpm (WOT)

Standard Model RangeBodensee Model Range

Standard ModelMain Jet Size9.9 hp15 hpPilot Jet

Bodensee ModelMain Jet Size9.9 hp15 hpPilot Jet

Float Height

950 ± 50 rpm 850 ± 50 rpm

4500–55005200-5700

#68#104#45

#68#103#45

0.61 ± 0.04 in. (15.5 ± 1.0 mm)

Special Tools

1. Carburetor Scale P/N 91-36392

55847

2

3

4

5

6

7

89

10

1112

1314

15

16

17 18

19

20

21

22

23

24

31

32

25

26

27

28

29

30

33

34

1

35

CARBURETOR

Page 3B-2 90-856159R1 AUGUST 1998

Carburetor

CARBURETOR

90-856159R1 AUGUST 1998 Page 3B-3

Carburetor

REFTORQUE

REF.NO. QTY. DESCRIPTION lb-in. lb-ft Nm

1 CARBURETOR (15)

11 CARBURETOR (9.9)

11 CARBURETOR (9.9 BODENSEE)1 CARBURETOR (15 BODENSEE)

2 2 SCREW (M4x10) 17.7 23 1 COVER4 1 GASKET

5 1 THROTTLE SCREW6 1 SPRING-Pilot Adjusting7 1 SCREW (M4x5) Drive Tight8 1 PLATE9 1 SCREW (M3x5) Drive Tight10 1 PILOT JET (#45) 10.6 1.211 1 PLUG 17.7 2

1 MAIN NOZZLE (15) 17.7 2

12 1 MAIN NOZZLE (15 BODENSEE) 17.7 21 MAIN NOZZLE (ALL 9.9) 17.7 2

13 1 O RING1 MAIN JET (#104) (15) 10.6 1.2

14 1 MAIN JET (#103) (15 BODENSEE) 10.6 1.21 MAIN JET (#68) (ALL 9.9) 10.6 1.2

15 1 SCREW (M4x5) 17.7 216 1 NEEDLE VALVE17 1 FLOAT18 1 FLOAT PIN19 1 GASKET20 1 FILTER

211 FLOAT BOWL ASSEMBLY (15)

211 FLOAT BOWL ASSEMBLY (9.9)

22 1 RETAINING RING23 1 CAP24 1 SEAL25 1 DIAPHRAGM 1526 1 SPRING27 1 COVER

28 3 SCREW (M4x8) 17.7 229 1 DRAIN SCREW (M4x5) 17.7 230 1 GASKET31 1 DRAIN SCREW (M5x6) 34 4.532 1 GASKET Not Included W/ 9.9 Bowl33 4 SCREW (M4x12) 17.7 2

34 1 CHECK VALVE (15)35 1 SEAL (BODENSEE)

CARBURETOR

Page 3B-4 90-856159R1 AUGUST 1998

Intake

1

3

4

5

6

7

8

910

11

12

13

2

3

6

110 4-Stroke Outboard Oil (92-828000A12)

110

CARBURETOR

90-856159R1 AUGUST 1998 Page 3B-5

Intake

REFTORQUE

REF.NO. QTY. DESCRIPTION lb-in. lb-ft Nm

1 1 INTAKE MANIFOLD2 1 GASKET3 2 DOWEL PIN4 4 BOLT (M6 x 40) 70 85 1 INSULATOR6 2 GASKET7 1 O RING

8 1 SILENCER9 DECAL-Warning, High Voltage10 1 PLATE11 2 COLLAR12 2 BOLT (M6 x 100) 88 1013 1 HOSE

CARBURETOR

Page 3B-6 90-856159R1 AUGUST 1998

Carburetor Adjustments

Idle SpeedNOTE: Before adjusting the idle speed make sure the throttle link rod has been properlyadjusted.

1. Measure the idle speed using the procedure below, adjust if necessary:

• Start engine and allow it to warm up.

• Attach a tachometer to the spark plug lead of cylinder #1.

• Measure idle rpm with outboard in neutral.

• Turn throttle stop screw in direction A or B until the specified idle speed isobtained.

NOTE: Turning throttle stop screw in (a) will increase idle speed while turning screw out (b)will decrease speed.

Idle rpm (Out Of Gear)

950 ± 50 RPM

a

b

LinkageREMOTE CONTROL MODELS

1. Connect throttle linkage and secure with screw.

NOTE: Linkage should extend 0.28 in. (7 mm) beyond barrel. Over-tightening screw maydamage throttle linkage.

c

a

b

a-Throttle Linkageb-0.28 in. (7 mm) Lengthc-Screw

CARBURETOR

90-856159R1 AUGUST 1998 Page 3B-7

TILLER HANDLE MODELS (SIDE SHIFT SHOWN)

1. Turn idle speed screw counterclockwise until screw is not touching throttle shaft arm.

ab

a-Idle Speed Screwb-Throttle Shaft Arm

2. Install throttle linkage on pulley and throttle barrel.

c

b

a

a

a-Throttle Linkageb-Throttle Barrelc-Pulley

3. Check to make sure throttle linkage is has free movement between throttle barrel andpulley.

NOTE: The throttle arm should remain stationary while checking for free movement ofthrottle linkage.

a

b

c

a-Throttle Barrelb-Pulleyc-Throttle Arm

CARBURETOR

Page 3B-8 90-856159R1 AUGUST 1998

4. Move throttle linkage forward until linkage comes to rest on the pulley boss.

a b

a-Throttle Linkageb-Pulley Boss

5. Tighten screw on throttle barrel to secure linkage.

NOTE: Over-tightening screw may damage throttle linkage.

NOTE: Check linkage for free movement on pulley. Verify throttle shaft arm in not stickingand returns to idle position.

a

b

a-Screwb-Linkage

6. Verify throttle arm does not hit the full throttle stop at wide open throttle. Gap betweenstop and throttle arm should be no more than 0.1 in. (2.54 mm).

c

ab

a-Throttle Stopb-Throttle Armc-Approximately 0.1 in. (2.54 mm) Gap

CARBURETOR

90-856159R1 AUGUST 1998 Page 3B-9

7. Turn idle speed screw in (clockwise) until it touches the throttle shaft arm, then turn anadditional 1/2 turn for initial setting.

a

b

a-Idle Speed Screwb-Throttle Shaft Arm

Choke1. Route choke cable through cable bracket and install retaining ring.

a

b

a-Choke Cableb-Retaining Ring

2. Set the choke cable to the off position (cable fully pushed in).

a

a-Choke Cable

CARBURETOR

Page 3B-10 90-856159R1 AUGUST 1998

3. Set choke shutter to the off position (shutter lever rotated fully counterclockwise).

4. Thread the ball socket end on shaft until ball socket aligns with ball on carburetor. Snapsocket onto ball.

NOTE: Verify choke goes to full choke with cable pulled out and returns to off position withcable pushed in.

ab

c

a-Threaded Ball Socketb-Ballc-Shutter Lever

CARBURETOR

90-856159R1 AUGUST 1998 Page 3B-11

Carburetor Removal1. Remove throttle linkage from carburetor barrel.

a

b

a-Barrelb-Throttle Link

2. Remove choke linkage (tiller handle models only).

a

a-Choke Linkage

3. Remove j-clips.

4. Disconnect breather hose from air intake and breather cover.

c

ab

d

a-J-Clips (2)b-Breather Hosec-Air Intaked-Breather Cover

CARBURETOR

Page 3B-12 90-856159R1 AUGUST 1998

5. Remove bolts.

6. Separate intake/carburetor assembly from powerhead.

56601

ab

c

a-Bolts M8x40 (4)b-Dowel Pin (2)c-Gasket-Manifold (Discard)

7. Remove air intake bolts.

8. Separate intake/manifold components from carburetor assembly.

56601

i

h

e

d

cb

a

f

g

g

a-Bolts-Air Intake M6x76 (2)b-Spacers (2)c-Plated-Air Intakee-O-Ring (Discard)f-Carburetor Assemblyg-Gasket (2) (Discard)h-Insulatori-Manifold

CARBURETOR

90-856159R1 AUGUST 1998 Page 3B-13

Carburetor Disassembly

1. Remove drain screw.

NOTE: Use an acceptable container to hold gas when draining float bowl.

2. Remove float bowl.

3. Remove cover.

a

b

c

d

e

f

gh

i

a-Drain Screw-M5x6b-Gasket-Drain Screwc-Screws (4)-M4x12d-Float Bowle-Valve

f-Gasket-Float Bowlg-Screw(2)-M4x10h-Coveri-Gasket

4. Remove float assembly.

a

b

c

d

a-Screw-M4x5b-Pinc-Needle Valved-Float Assembly

CARBURETOR

Page 3B-14 90-856159R1 AUGUST 1998

5. Remove jets and nozzle.

a

b

c

d

e

f

g

a-Main Nozzleb-O-Ringc-Main Jetd-Pilot Jete-Seal Capf-Plateg-Screw-M3x5

6. Remove diaphragm and filter.

gh

j

k

f

d

i

a

b

ce

a-Filterb-Screw-M4x5c-Gasket-Drain Screwd-Screws (3)-M4x8e-Basef-Spring

g-Ringh-Capi-Diaphragmj-Plungerk-O-Rings (2)

CARBURETOR

90-856159R1 AUGUST 1998 Page 3B-15

Cleaning/Inspection/Repair

1. Inspect carburetor body for cracks/damage/contamination. Replace/clean as neces-sary.

NOTE: Use a petroleum based solvent for cleaning. Blow out all passages with compressedair, never use a wire.

2. Inspect jets and nozzle for contamination. Replace if necessary.

b

da

c

a-Main Jetb-Pilot Jet

c-Valved-Main Nozzle

3. Inspect needle valve for wear. Replace if necessary.

NOTE: Check tip of needle valve for wear.

4. Inspect float for cracks/damage. Replace if necessary.

5. Inspect diaphragm, o-rings and gaskets for damage. Replace if necessary.

6. Inspect filter for contamination/damage. Clean/replace if necessary.

CARBURETOR

Page 3B-16 90-856159R1 AUGUST 1998

Carburetor Reassembly

1. Install diaphragm and filter.

f

ed

bk

ac

g

h ij

a-O-Rings (2)b-Plungerc-Diaphragmd-Cape-Ringf-Spring

g-Baseh-Screws (3)-M4x8i-Gasket-Drain Screwj-Screw-M4x5k-Filter

2. Install jets and nozzle.

a

bc

d

e

f

g

a-Plateb-Screw-M3x5c-Pilot Jetd-Seal Cap

e-Main Nozzlef-O-Ringg-Main Jet

CARBURETOR

90-856159R1 AUGUST 1998 Page 3B-17

3. Install needle valve onto float hinge.

56677

b

c a

a-Floatb-Needle Valvec-Pin

4. Install float assembly.

56676

a

bc

a-Floatb-Pin-M4x5c-Screw

CARBURETOR

Page 3B-18 90-856159R1 AUGUST 1998

Float Height Measurement1. Measure float height as shown, if out of specification replace.

56675

P/N 91-36392

Carburetor Float Height

0.61 ± 0.04 in. (15.5 ± 1.0 mm)or

36/64 in. - 41/64 in.

2. Install drain screw, float bowl and cover.

cb

a

e

i

d

h

g

f

a-Gasketb-Coverc-Screw (2)-M4x10d-Valvee-Gasket-Float Bowl

f-Float Bowlg-Screws (4)-M4x12h-Gasket-Drain Screwi-Drain Screw-M5x6

CARBURETOR

90-856159R1 AUGUST 1998 Page 3B-19

Carburetor InstallationElectric Choke Models Installation

1. Assemble solenoid components as shown.

a

bc

d

ef

a-Grommetb-O-ringc-Hookd-Solenoide-Bracketf-Screws M5x8 - Torque to 30 lb-in. (3.4 Nm)

2. Install solenoid to carburetor assembly. Push grommet over pin and secure spring tocarburetor with O-ring.

56750

ab

c

a-Solenoid Assemblyb-Grommetc-O-ring

3. Secure solenoid bracket to powerhead with two (2) bolts M6x16. Connect BLUE to YEL-LOW/BLACK and BLACK lead to BLACK lead from remote control.

56751

a

b

a-Bolts M6x16 (2) - Torque to 70 lb-in. (8 Nm)b-Solenoid Bracket

CARBURETOR

Page 3B-20 90-856159R1 AUGUST 1998

1. Assemble intake/manifold components to carburetor assembly.

2. Secure air intake with bolts.

56601

ab

cb

d

e

h

fg

i

a-Manifoldb-Gasket (2) (New)c-Insulatord-Carburetor Assemblye-O-Ring (New)f-Plateg-Spacersh-Air Intakei-Bolts (2)-M6x 100

Carburetor Mounting Bolts

88 lb-in. (10 Nm)

CARBURETOR

90-856159R1 AUGUST 1998 Page 3B-21

3. Install intake/carburetor assembly onto powerhead.

56601

a

bc

d

a-Gasket-Manifold (New)b-Dowel Pin (2)c-Intake/Carburetor Assemblyd-Bolts (4) M6x40

Manifold Mounting Bolts

70 lb-in. (8 Nm)

4. Install j-clips.

5. Connect breather hose to air intake and route hose through j-clips.

a b

a-J-Clips (2)b-Breather Hose