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.

RECOMMENDED OE TOOLS:

C161-1: main jet wrench

C161-9: main discharge wrench

C161-72-3: bushing driver

C161-85: fuel valve seat wrench

GENERAL HAND TOOLS:

1/2” open end wrench

1/4” blade screw driver

1/8” blade screw driver

long nose pliers

6” depth gauge

1/4” round file

light hammer

long rod or punch

DISASSEMBLY

REMOVAL OF THROTTLE BODY ASSEMBLY

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

DISASSEMBLY OF THROTTLE BODY

  1. Press against end of float axle (13) 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 (14) and fuel valve needle (part of 12).
  2. Remove body to body gasket from machined surface of throttle body (48), then remove venturi (16).

NOTE: Some 62AJ-series carburetors have venturi held in place by screw (8) and lockwasher (7).

  1. Remove fuel valve seat (12) and fiber washer (11), using C161-85 wrench.
  2. Remove economizer jet (46) and fiber washer (47), using small screwdriver. (Used only with 62-J and 162-J series carburetors).
  3. Remove idle jet (45) from machined surface of throttle body, using small screwdriver.
  4. Remove idle adjusting needle (6) and friction spring (5) from side of throttle body.
  5. Back out throttle stop screw (52) flush with end of lever (55), close throttle valve and mark throttle body and lever as a guide to correct assembly of parts.
  6. File off riveted end of throttle plate screws (57) flush with throttle shaft. Use care not to damage throttle plate or throttle bore.
  7. Remove throttle plate screws, throttle plate (58) and throttle shaft and lever assembly (51).
  8. To remove throttle shaft packing (3) and retainer (49), screw fine thread taper tap into packing retainer until firmly seated in retainer. Use tap 1/16” larger than ID of retainer. Insert long punch or rod through opposite shaft hole and drive out retainer and packing with tap. Repeat operation at opposite shaft hole.

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 component parts of assembly are damaged.

  1. Remove fuel inlet fitting (10) wit scree (if used) and gasket (9).