NOTE: the instructions below reference OE style Zenith tools. These tools are not available aftermarket, we use hand tools found at any hardware store and modify as needed.

DISASSEMBLY

REMOVAL OF THROTTLE BODY ASSEMBLY

  1. Remove four bowl to body assembly screws (38) and lockwashers (39), using a screwdriver.
  2. Raise throttle body slightly and separate bowl to body gasket (15) from fuel bowl assembly, then lift off throttle body carefully to avoid damage to the floats.

DISASSEMBLY OF THROTTLE BODY

  1. Press against end of float axle (14) at slotted side of hinge bracket to force axle through hinge bracket, using a small screwdriver. Then remove float axle completely with fingers from opposite side and remove float assembly (51), with fuel valve needle.
  2. Remove bowl to body gasket (15) from machined surface of throttl ebody (3), then remove venturi (50).
  3. Remove fuel valve seat (52) with fiber washer (53), using C161-82 wrench.
  4. Remove idle adjusting needle (12) and friction spring (13) from side of throttle body.
  5. Remove idle jt (54) from passage in machined surface of throttle body near fuel valve seat, using a small screwdriver.
  6. Back out throttle step screw (66) flush with end of lever (58), close throttle and mark levers and throttle body as a guide to correct assembly of parts.
  7. Loosen throttle clamp lever screw (10) and remove lever (9), cotter pin (11), spring retainer (8), spring (7) and throttle lever bushing (6), (if carburetor includes these parts).
  8. File off rivited or peened end of throttle plate screws (68) flush with throttle shaft. Use care not to damage throttle plate or throttle bore.
  9. Remove throttle plate screws, throttle plate (2) and throttle shaft and lever assembly (57).
  10. To remove throttle shaft packing (4) and retainer (70), screw a 5/16”-24 thread tap into packing retainer until firmly seated, then insert long punch or rod through opposite shaft hole and drive out retainer and packing with tap. Repeat operation for packing and retainer at opposite side.

NOTE: DO NOT remove throttle plate, throttle shaft and lever assembly, throttle packings and retainers from throttle body unless shaft is bent or unless other components of assembly are damaged.

  1. Remove fuel inlet plug (55) and screen (if used).

DISASSEMBLY OF FUEL BOWL

  1. Remove main jet adjustment assembly (36) and fiber washer (35) from bottom of bowl, using 1/2” wrench.