How to Rebuild a 5Hp Outboard Carburetor

Written by will charpentier
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Unlike scheduled maintenance -- oil changes, water pump inspections and fuel filter changes -- a carburettor rebuild is done when necessary. When you rebuild the carburettor of a 5-horsepower outboard motor, you disassemble the carburettor, replace damaged and broken parts, clean everything and put it all back together. The process is messy. Once the job is complete, however, your carburettor will have new gaskets and seals, and the fuel passages will be free of dirt, oil, grease and other contaminants.

Skill level:

Things you need

  • Standard screwdriver
  • Shallow pan
  • Carburettor cleaner
  • Carburettor rebuild kit
  • Torque driver

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    Disassembly and Cleaning

  1. 1

    Locate the low-speed needle and needle spring protruding from the side of the carburettor. Remove the pilot jet from the carburettor.

  2. 2

    Remove the air jets from the cast pockets in the carburettor throat with a standard screwdriver. Mark the air jets as you remove them. Keep the air jets separated to ensure they are installed correctly.

  3. 3

    Hold the carburettor and diverted over a small basin. Remove the float bowl mounting/drain screw. Remove the float bowl from the carburettor. Drain any fuel still in the bowl. Discard the gasket.

  4. 4

    Remove the hinge pin from the float valve. Remove the float and the valve. Remove the screw that holds the main jet and nozzle in the carburettor body. Lift the main jet and the nozzle from the carburettor.

  5. 5

    Fill a shallow pan with carburettor cleaner. Immerse the nonrubber parts in the cleaner.


  1. 1

    Discard out all gaskets, O-rings and seals that you removed from the carburettor. Ensure all other parts are clean. Compare them to the parts in the carburettor rebuild kit to verify that they are identical to the replacement parts, except for normal wear and tear.

  2. 2

    Return the main nozzle and main jet to the carburettor body. Thread the mounting screw into its bore and secure the nozzle and jet. Tighten the screw snugly.

  3. 3

    Return the float and float valve to the float bowl and secure them in place with the hinge pin. Invert the float bowl so that the rim is horizontal. Measure the distance between the rim of the float bowl and the top of the float with a vernier caliper -- the proper measurements are 0.047 of an inch and 0.055 of an inch. If necessary, bend the metal tap that carries the float to achieve this measurement.

  4. 4

    Place the float bowl gasket in the groove in the carburettor body and install the float bowl on the carburettor. Put a new gasket on the bowl drain screw and thread the bowl's mounting/drain screw into the float bowl. Tighten the screw with a torque driver to between 84 and 138 pound-inches.

  5. 5

    Reinstall the air jets in the cast pockets of the carburettor throat from which you removed them.

  6. 6

    Return the pilot jet to the carburettor. Replace the low-speed needle and needle spring. Tighten the needle until it contacts the valve. Back the needle out 2 1/2 turns.

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