FUEL SYSTEMS

72085

ROCHESTER 4 BARREL CARBURETOR

5 C

INDEX

Table of Contents
Page Rochester 4 Barrel Carburetor . . . . . . . . . . . . . 5C-1 Torque Specifications . . . . . . . . . . . . . . . . . . 5C-1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 5C-2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-2 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-2 Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-3 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-4 Accelerator Pump . . . . . . . . . . . . . . . . . . . . . 5C-4 Air Valve Dashpot . . . . . . . . . . . . . . . . . . . . . . 5C-5 Air Valve Spring Windup . . . . . . . . . . . . . . . . 5C-5 Float Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-6 Choke Coil Rod . . . . . . . . . . . . . . . . . . . . . . . 5C-6 Vacuum Break . . . . . . . . . . . . . . . . . . . . . . . . 5C-7 Float Weight . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-8 Float Level Adjustments . . . . . . . . . . . . . . . . 5C-8 Preliminary Idle Speed and Mixture . . . . . 5C-10 Final Idle Speed and Mixture . . . . . . . . . . . 5C-10

INDEX
5C - ROCHESTER 44 BARREL CARBURETOR 5C-0 ROCHESTER BARREL CARBURETOR 90-806535940 893

Rochester 4 Barrel Carburetor

Torque Specifications
Fastener Location Carburetor To Manifold Fuel Line to Carburetor Fuel Inlet Filter Nut lb. ft. (Nm) 13(15) 18(24) 18(24)

Tools
Part Number 91-59339 91-36392 Obtain Locally Tachometer Universal Carburetor Gauge Torx Screwdrivers #9,#20 & #25 Description

Boroughs Special Tool and Equipment Inc. 2429 N. Burdick Street Kalamazoo,MI 49007 (616) 345-5163 BT 8128 B BT-8420 A Float Gram Scale Float Level Gauge

Kent-Moore Special Tools 29784 Little Mack Road Roseville,MI 48066 (313) 574-2332 J9789-118 J22769 Carburetor Stand Needle Valve Seat Remover

Wagner Special Tools Wagner Instruments P.O. Box 1217 Greenwich,CT 06836 (203) 869-9681 Model G.D. 150 Gram Scale (with Round Tip)

INDEX
90-806535940 893 ROCHESTER 4 BARREL CARBURETOR - 5C-1

Specifications
Units of Measurement In. (mm) Engine Model Carburetor Type Mercury Number (Manufacturer Number) Primary Jet Size Primary Metering Rods Secondary Metering Rods Float Level Pump Rod Hole Location Accelerator Pump (Note 2) Air Valve Dashpot (Air Valve Rod) Vacuum Break Air Valve Spring Windup Choke Coil Rod (Note 3) Idle Mixture Preliminary Setting Float Weight (Max) 1347-9661 (17080565) .069 .042 CL 15/64(5.9) Inner 23/64(9) .025(0.64) .080[5/64](2.0) 70-90 Grams Top of Rod even with Bottom Of Hole 2-3 Turns 8.3 Grams MCM 5.0LX
00000 MIE 5.7L Competition Ski

Rochester 4MV 1347-9415 (17085013)

Note:1. All measurements are +/ 1/64in. (0.4mm) Note: 2. Accelerator Pump measurement taken from flame arrestor surface to pump stem with throttle plates closed Note:3. Choke valve must be closed, choke rod in bottom of choke lever slot and choke coil rod pushed down to end of travel.

Identification

Fuel Filter

a
a b c d e f Fuel Line Fuel Inlet Filter Nut Gasket (Large) Gasket (Small) Filter Spring

f d b c e
72087

72085

INDEX
5C-2 - ROCHESTER 4 BARREL CARBURETOR 90-806535940 893

Exploded View

2 3 7 6 5 4 1

24 23 33
1 - Air Horn Assembly 2 - Screw 3 - Hanger 4 - Metering Rod, Secondary 5 - Screw 6 - Screw 7 - Screw 8 - Lever 9 - Roll Pin 10 - Pump 11 - Spring 12 - Needle and Seat 13 - Gasket 14 - Pull Clip 15 - Gasket 16 - Metering Rod, Primary 17 - Jet, Primary 18 - Float Assembly 19 - Pin, Hinge - Float 20 - Lever, Intermediate Choke 21 - Rod 22 - Clip 23 - Rod 24 - Clip 25 - Screw 26 - Control 27 - Hose 28 - Power Piston 29 - Retainer, Power Piston 30 - Retainer, Pump Discharge Ball 31 - Ball, Pump Discharge 32 - Spring, Power Piston 33 - Insert, Float Bowl 34 - Float Bowl 35 - Screw, Idle Stop 36 - Spring, Idle Stop Screw 37 - Spring, Filter Nut 38 - Filter, Fuel Inlet 39 - Nut, Fuel Inlet 40 - Gasket 41 - Gasket 42 Rod

27 25 26 18 14

15

16

19 29 28 30 12 32 17

10 42

22 21 22 13 31 34 36 20 35 11

37 41 43

38 40 39

45 44
72694

INDEX
90-806535940 893 ROCHESTER 4 BARREL CARBURETOR - 5C-3

Adjustments
! WARNING
Avoid gasoline fire or explosion. Improper installation of brass fittings or plugs into fuel pump or fuel filter base can crack casting and/or cause a fuel leak. Apply #592 Loctite Pipe Sealant with Teflon to threads of brass fitting or plug. DO NOT USE TEFLON TAPE. Thread brass fitting or plug into fuel pump or fuel filter base until finger tight. Tighten fitting or plug an additional 1-3/4 to 2-1/4 turns using a wrench. DO NOT OVERTIGHTEN. Install fuel line. To prevent over-tightening, hold brass fitting with suitable wrench and tighten fuel line connectors securely. Check for fuel leaks.

2. Pump rod must be in inner hole of lever.

a
72088

a - Pump Rod b - Inner Hole

3. Close throttle valves completely and measure from flame arrestor mounting surface to top of pump plunger stem.

Accelerator Pump
1. Back out idle stop screw until it no longer contacts throttle lever. b

b a c
72089 a - Flame Arrestor Mounting Surface b - Pump Plunger Stem c Measurement 23/64 (9 mm)
72081

a
a - Idle Stop Screw b - Throttle Lever

INDEX
5C-4 - ROCHESTER 4 BARREL CARBURETOR 90-806535940 893

4. While supporting lever, bend tip of pump lever to obtain specified dimension in Step 3.

Air Valve Spring Windup

1. Rotate gram scale until air valve begins to open; check scale reading for correct specifications. b

b
72090

a - Tip of Pump Lever b - Support as Shown

Air Valve Dashpot

72092

1. Seat vacuum break diaphragm and close air valve completely. Bend rod to adjust gap to specifications.

a b c d

Carburetor Casting Gram Scale Contact Area of Arm on Air Valve Rotate

a b
72091

a b c d

Push in Completely Bend Here to Adjust Measurement .025 In. (0.64 mm) Fully Closed

INDEX
90-806535940 893 ROCHESTER 4 BARREL CARBURETOR - 5C-5

2. To adjust spring windup, hold tension spring screw and loosen Allen head screw. 3. Adjust tension and retighten Allen screw securely. c

2. Tap float gauge down lightly to assure free movement.

a b

72082 72093

a - Gauge

a - Increase b - Decrease c - Screw

3. If float requires adjustment, refer to Float Adjustments later in this section, for adjustment procedure.

Choke Coil Rod Float Level

1. Start engine to fill float bowl, run at idle and insert float gauge into hole next to flame arrestor stud. b a 1. Push choke coil rod down.

b a
72083

a - Gauge Hole b - Gauge

72096

a - Vacuum Break Choke Lever b - Choke Coil Rod

INDEX
5C-6 - ROCHESTER 4 BARREL CARBURETOR 90-806535940 893

2. Choke coil rod top must be even with bottom of hole in vacuum break choke lever.

Vacuum Break
1. Seat vacuum break control diaphragm by pushing in direction shown by arrow.

b a a

72096

72097

a - Top of Rod b - Bottom of Hole

a - Vacuum Break Control Diaphragm

3. Bend rod to adjust.

2. Rotate vacuum break choke lever counterclockwise until tang contacts vacuum break rod. Choke rod must be at bottom of choke shaft lever slot.

c a
72097 72095

a - Tang b - Choke Rod c - Vacuum Break Rod

a - Bend Here

INDEX
90-806535940 893 ROCHESTER 4 BARREL CARBURETOR - 5C-7

3. Bend tang as necessary to obtain specified choke valve gap. b

Float Level Adjustments

1. If a new float or needle and seat are used, bend float arm slightly upward at notch for easier adjustment.

b a
72097 72130

a - Tang b - Gap 5/64 In. [.080 In.] (2.0 mm)

a - Float b - Float Arm Notch

a. Hook needle pull clip over edge of float arm closest to pontoon.

Float Weight
1. Assemble float scale according to instructions with scale. 2. Compare float weight to specifications. a a

72130

b
a - Pull Clip b - Float Arm

b
72122

a - Float Scale b - Float

3. Replace float if it exceeds specifications.

INDEX
5C-8 - ROCHESTER 4 BARREL CARBURETOR 90-806535940 893

b. Install retaining pin into float arm and install float and needle into bowl. c

2.

Hold hinge pin firmly, turn carburetor upside down and measure from casting surface to toe of float with universal carburetor gauge. Check specifications.

3. Bend at float arm notch for adjustment to specifications. If float requires adjustment a b

72094 72115

a - Float b - Needle c - Retaining Pin

IMPORTANT: Top of retaining pin must extend above Float Bowl casting by .010 in. (0.254 mm) for good pin retention.

b
72610 a - Hinge Pin b - Universal Caberutor Gauge (P/N 91-36392) c - Notch-Bend Here

INDEX
90-806535940 893 ROCHESTER 4 BARREL CARBURETOR - 5C-9

Preliminary Idle Speed and Mixture

IMPORTANT: DO NOT turn idle mixture needles tightly into seat, as damage to needle and/or seat may result. Note: If a new or rebuilt carburetor has been installed, turn each idle mixture needle until it LIGHTLY contacts seat, then back out 2 or 3 turns. This will provide a sufficient setting to allow starting the engine. Initial start setting; make final adjustments with engine running.Refer to Final Ilde Speed and Mixture 1. Turn idle stop screw out until it does not contact throttle lever, then turn in until it just contacts throttle lever. b

Final Idle Speed and Mixture

IMPORTANT: Boat MUST BE in the water and engine at normal operating temperature to accurately check and adjust idle speed and mixture. Carburetor should be set so that engine idles smoothly, with boat in the water, engine at normal operating temperature and drive unit in forward gear. To adjust idle speed and mixture, proceed as follows: IMPORTANT: DO NOT attempt to compensate for other engine problems (incorrect ignition timing, faulty ignition components, low compression, vacuum leaks, etc.) with carburetor adjustments. This will only cover the problem which must be corrected if engine is to achieve maximum fuel economy and performance. 1. Connect a shop tachometer to engine. 2. Start engine and run at 1500 RPM until engine reaches normal operating temperature.

! WARNING
DO NOT leave the helm unattended while performing idle speed and mixture adjustments, following. BE CAREFUL NOT TO ACCIDENTALLY ACCELERATE ENGINE WHILE PERFORMING ADJUSTMENTS. 3. With boat in open water, place remote control in forward gear, idle position. 4. Disconnect throttle cable brass barrel from anchor stud. BE SURE NOT TO LOSE SPACER ON ANCHOR STUD. 2. Turn idle needles until LIGHTLY seated then back out 2 to 3 turns. 5. Adjust idle speed adjustment screw to obtain specified RPM. 6. With engine running at specified RPM, adjust idle mixture needles as follows: a. Turn idle mixture needle in (clockwise) until the engine speed begins to drop due to lean mixture. b. Turn idle mixture screw out (counterclockwise) until the speed begins to drop due to a rich mixture. a
a - Idle Needles
72098

a
72081

c. Turn screw in to a point between these two extremes to obtain maximum engine smoothness and RPM. d. Repeat procedure with other needle. e. Readjust idle speed adjustment screw, if necessary, to obtain specified RPM.

IMPORTANT: Do not turn idle mixture screws tightly against seat, as damage to seat and/or needle may result.

INDEX
5C-10 - ROCHESTER 4 BARREL CARBURETOR 90-806535940 893