Rebuilding an Evinrude carburetor is just tear it down and put it back together. It's "spring cleaning." Any time you rebuild Evinrude carburetors, good shop practice dictates that you don't just tear it down and put it back together; instead, you install new parts in it. Finding the required parts isn't a scavenger hunt, either. Everything you need is found in an Evinrude carburetor rebuild kit.
Hold the carburetor over a shop sink and remove the drain screw from the bottom of the carburetor bowl with a screwdriver. Drain any fuel that may remain in the bowl and discard the gasket from the drain screw.
Unscrew the mixture screw and its spring from the top of the carburetor and unscrew the seven screws that hold the carburetor cover. Remove the cover and the gasket from the carburetor. Turn the carburetor upside down and remove the float bowl, the check ball, check valve cap and gasket
Push the hinge pin out with a punch. Separate the float and float valve from the carburetor as a unit and separate the float from the float valve and gasket from the float. Pull the high speed jet from the carburetor.
Take the the idle speed screw and its spring out of the boss on the side of the carburetor. Remove the cover on the bottom of the float bowl and remove the spring, the diaphragm, the retainer and O-ring as well as the check valve assembly from the carburetor. Take the accelerator pump cover off and remove the diaphragm and plunger.
Clean everything with isopropyl alcohol and blow each piece dry with compressed air, using a compressor and air hose.
Lay out the parts of the carburetor rebuild kit and identify each. Install the check valve assembly, O-ring, retainer, diaphragm and spring, in that order into the bottom of the float bowl. Ensure the retainer's flat side is against the check valve assembly. Position the diaphragm so the outer rib fits in the cover groove.
Thread the high-speed jet into place in the carburetor body. Use a new gasket and install the float valve seat. Insert the float valve into the valve seat.
Use the hinge pin to install the float. Check float height adjustment using the cutout marked on the float gauge. Bend the float arm so that it rests between the notches on the gauge.
Attach the end cap. Install a new gasket on the float bowl and attach the the float bowl to the carburetor, tightening the float bowl attachment screws to 8 inch-pounds with a torque wrench, according to the sequence stamped on the top of the float bowl.
Thread the idle speed adjustment screw and its spring into the vertical boss on the carburetor's side until it barely touches the idle adjustment lever. Use a new gasket when you install the carburetor cover on the carburetor body. Tighten the cover screws to 8 inch-pounds using a torque wrench, in the sequence stamped on the face of the cover. Thread the idle mixture screw and its spring into the round boss on the cover until it lightly touches the seat.
Items you will need
- Evinrude carburetor rebuild kit
- Torque wrench
- Isopropy alcohol
- Compressed air
- Work in an organized, clean space and cover the parts with a clean shop cloth after they've been cleaned. This keeps foreign matter from ending up in the finished assembly.
- Before beginning, ensure all new components are completely clean and serviceable. Compare parts from the replacement kit to the parts removed from the carburetor.
- Replace all O-rings or seals when rebuilding a carburetor.
- "Evinrude Repair Manual -- 2.5 to 250 HP Models, 2002-2007"; Seloc Marine; 2007