How to Rebuild a Holley Marine Carburetor
Holley marine carburetors are reliable and popular with both recreational and commercial boaters. When in proper working order, they deliver a precisely metered air/fuel mixture to the engine. However, old gas, bad gas or solid particulates in the fuel tank can lead to reduced performance or even non functionality. Carburetors can be rebuilt at home with a rebuild kit fairly easily without any special tools or training, restoring the performance of your Holley carburetor.
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Things You'll Need
- Holley marine carburetor rebuild kit
- Digital camera or cell phone with camera
- Flat screwdriver
- Phillips screwdriver
- Open end wrench set
- Dental pick
- Gasket scraper
- Pliers
Instructions
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Carburetor Removal
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1
Label each linkage and hose going to the carburetor with a piece of tape and pen or marker. Take several pictures of the assembled carburetor with a digital camera or cell phone. The pictures will be valuable for reassembly. Carefully remove all the clips or retainers from the linkages and store them in a safe place.
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2
Remove the clamps from any fuel and vacuum hoses with pliers or a screwdriver using screw clamps, and remove the hoses from the carburetor. Be mindful that the hose ends may be 'cooked' on or otherwise stuck in place and may need to be cut off the nipples or barbs. Hoses may also be dry-rotted or cracked and require replacement. Grasp the hose with the pliers to try and rotate and pull it off before resorting to cutting the hose.
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3
Remove the air cleaner (if it has one) and remove any braces that may be connected to the carburetor. Remove the carburetor mounting bolts with the appropriate sized wrench (size and pattern may vary by model) and lift the carburetor from the intake/plenum. Stuff a clean rag into the intake ports and scrape off the old gasket from the intake manifold and the bottom of the carburetor with the gasket scraper.
Carb Rebuild
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4
Remove the screws holding the float bowl on with a Phillips screwdriver. Carefully remove the float bowl gasket with a gasket scraper. Remove the needle valve and seat from the front of the bowl with a flat screwdriver.
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5
Remove any jets that are accessible in the bowl area of the carb with a flat screwdriver. These are made of brass. Take care not to damage or deform the jet orifices during removal and replacement. Remove any atomizer tubes that are present.
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6
Examine the accelerator pump. The check ball should appear clean and be free to move and the pump diaphragm must be free of holes or visible damage. Spray the check ball with carburetor cleaner to wash off any varnish or deposits. Remove any rubber or fiber seals that are accessible with your dental pick.
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7
Spray carburetor cleaner into all jets, fuel passages and air passages along with any nooks where varnish may be hiding. Wear goggles when spraying the cleaner as it is a strong solvent and can cause damage if splashed or sprayed into the eyes. Perform the cleaning in an area with lots of fresh air and no sources of ignition such as sparks, flames or cigarettes. Allow all parts to dry completely.
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8
Replace any seals or gaskets that were removed. Rubber seals should go on without being twisted or deformed and the paper/fiber gaskets should go on clean and dry. Discard and replace the float needle(s) and reinstall all of the jets. Reinstall the float bowl. Position the carburetor back onto the motor and reinstall the hoses and linkages. Torque down the carburetor to the intake with the appropriate wrench (varies by model).
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1
Tips & Warnings
Muffin pans are useful for organizing, containing and segregating the small parts that are removed.
Use caution when cleaning with aerosol-based carburetor cleaners. They are strong solvents and can cause bodily injury if squirted into an eye or any membrane surfaces.
