General Instructions

• Take lots of pictures as you take your carburetor apart. This will give you a reference of where
things go.
• Using a cookie sheet with folded up sides will help keep parts from falling on the floor.
• We suggest not removing the throttle shaft, valves, or choke shaft unless they are corroded, or
very dirty. These parts can be easily damaged and are difficult to re-assemble.
• Instruction sheets that come with our carburetor kits are somewhat generic. It may not match
your parts exactly.
• Do NOT use WD-40 around your carburetor. It reacts with ethanol.
• Using Silicon Spray Lubricant on the gaskets will help with sticking in case you need to take the
carburetor apart again.
• Be careful after taking the top of the carburetor off. Turning the carburetor upside down may
cause parts to fall out and you won’t know where they were.
• Screws and jets that are frozen can often be removed after heating outside the screw or jet.
• Stuck check balls can be removed by heating the outside of where the check ball resides and
tapping the carburetor on the work bench.
• Do not discard any parts until complete done. You may have to refer for size, or matching.

Cleaning:

• Clean with carburetor dis-assembled.

• Soak all parts except rubber & electrical in Simple Green for 2 hours. Aluminum parts will get
discolored if left longer.
• Wash parts with hot water if available to remove all chemicals.
• Blow out each passage way taking special notice of the smaller ones. Test each passage that air
goes through the entire passage.
• Blow out the idle mixture hole.
 • Check any hole above the idle mixture hole (inside the bore). This is the idle discharge and often
becomes plugged.
• A tooth brush can facilitate cleaning parts.
• Soda blasting, then washing again will make the carburetor look good any will clean any minor
deposits.
• Any corrosion, or deposits that are hard to remove may indicate the passages are also corroded
and the carburetor should be replaced.
• If your engine has been sitting for 6 months or more, the gas has probably turned, and the gas
tank will need to be cleaned as well as the fuel lines. Flushing new gas through the tank will not
be enough.

Assembly:

• Do NOT apply any gasket sealant on any of the gaskets. Gas will break sealant part and the
particles will clog the small passages.
• Test your float.
o Brass floats should be immersed into hot water. As the air inside expands any leak will
be noticeable with air bubbles.
o Plastic, or Nitrophyl floats should be weighed. The weight is in grams. Check our
technical pages for any weight specification that we may have.
• Most gaskets will fit as expected, but you may have to trim some, especially under the venturis.
• Your kit may include multiple gaskets in order to get better coverage out of the kit. Use the one
that fits the best. Look for any opening the gasket may leave allowing air into the carburetor.
Some holes may be casting holes that don’t lead to anything and do not have to be covered.
• Mounting gaskets for multiple bore carburetors do not have to have matching holes. Example a
four-barrel gasket can be open in the middle instead of 4 holes as long as the carburetor has
some kind of passage between bores. The passage is between primary, or secondary, not both.
• When adjusting the float be careful not to put any pressure on the needle. The viton tip is easily
damaged.
• Most idle mixture screws can be cleaned using a soft wire wheel. Inspect for any scoring, which
would indicate over tightening. Screw with scoring should be replaced.

Accelerator Pumps:

• On leather cups run your finger around the inside of the cup to break any manufacturer sealant.
• Apply 2 drops of oil to cups (leather, or rubber) before inserting into carburetor. Do not soak the
cup in oil. The swelling of the cup needs to happen inside the carburetor. Allow the 2 drops of oil
and the gas to do its job naturally.
• Twist the pump as you are inserting to help keep the cup from curling or folding over.
• Test your accelerator pump circuit before putting the top of the carburetor back on. Our
technical pages have instructions on how to do this for most carburetor types.
• Pump wells are usually slight tapered, and the pump will not seal until it gets towards the
bottom.
 ,. J,0,02
ZENITH CARBURETOR RESTOROGRAPH 63, 63M & '263M
SERIE?

l I- 1
v-'
o.,..;z
l KEY
HO . PARTHAME:

I SCR£W~Bo:;..j \O Body .
i LOC.KWASHE:it
J SCRr.~Throlllt ·Pl&:t
~ PLATE-Throttle
~ SCREW-VM:u1,11n Channtl
,
6 P.USHtNO-Th·rollle Shaf\
WAS2-iER'.:..Shaft P~klni
R.ETAJK f.R-Thrut .Sh.Pk i•
8
9 SHAFT'-: LEYEi-Throtllt
11 SPa.INO-Th11)\.StvP Screw
11 SCRE'I-Throttlt Stop
12 SCRE'I-Throt.L'evcr CIIJT\P
· 13 L·r.v£a-Throttle CILDIP
14 LEYi::lt-T-1\lottlt $4r1p
1:1 SHAFT-Throttle
16 PLUO.-V11.:uum S{)uk Chlllilr.l
1"J PLUO-F'!lttr
13: WA&iEi.--f'IHe, Plui
1P SCi.EEN-1'\lel f'Utu
~ BO DY-Unloo
%1 WA.SliE1t-U1llon Bod., .
n NEEOLE-ldlc A.d,lus1Ln,
23 8P'K.1NO-ldl1 Adj. Nn-dle
2,-4 JE7-ldle
2:1 lf ASH EK--F'\J e I V r.l v 11 .S ut
211 YA.LYE &i SEAT-r\al
21 AXLL-r'l.o&4
2:a FLOAT
ZS OA.Sl(ET-Bowl 10 Body
3? YE.NTURS
3J YALYl::-Po11e1 Jel
~ YENT-'tfdl
~ YALYE-Puc:ip ClHrl
3' SH Ar"'T-C h ~ e
J1 IASHOl-Ch. ~ - Thr.ist
J:I 8Ci.£ lf-COYCI P l.Ltt
3' LOC.I( IA.Sit EK . ,.
40 PLATE-Cbok.e Sh. Conr
4I CJ ASX IT-Cov111 Pl LLe
42 BO n. -P\J C I

..,
-43 JA$~H:~-M I.in J .. 1
i-4 J ET-M&!n .
l"ASliEll.-441..ln Puu.ac P lue
~ P'I..UO or AOJ.-lol&.io Jtl
41 • ASaEJt-ro WCI/ A.eccl .J el
-~2 <8 •~Ea-Puu..i;r Plue
~ P1... uc-P L.Sl LI; C
:10 J IT·-Po"Wcr u Acer.I tr IJ In,
:II PLUG or YAL\'E-Bo11·I Or&!n
H PLUC-lntue Dr&!n
:IJ J ~Ei.-Ch.Sh. P a.cil ni
:14 B ~AC1' IT-Chol o
!'>!'> LOCKl'ASHE.K
!'>-. S{; 1u: W-Buck. et
!'>1 S<'R.Elf-1'\Jbc Cl ll'DP
~ LE YEi.-Choke
!'>9 SC R.EW--Ch. LcYl"f S w1 vel
GO. SC~.EW-Ch. Lever Cluiw
61 p L:\ TE-Cho.: C ,I
62 l..00(1.-\SREi
iJ SC'R£Jr-Chok.e Pta:,
G-4 'IASREJL-0\~hu~ Jct
1 DISAS SEM!4. Y 6:1 JIT- 01.x:hu,e
Si •
PUWP PISTON
O l sa .\Hmb iy con,ist:1 of separating the carburetor Into two basic groups: li1 ll"ASJ-i Ea -1 nl d l-'I 11,
fuel bov.·I a 11d air lnlakt•lhrollle body and lhe c.Jlsn~stinbly cif t'.tlch of
0
~ PLUU-F'uri lr.11'1
thest- ~roups . l :H' tspl()dtd illuslrallon· abvv~ u u ~uldt: f{ir disasHmbly l:i9 L tX-lo: 'II' \Sll~:K
d 11 d r l' i1 Hemb !_,. . · · · 'j 0 S{ "IU:.:11-Vt-11 '. 'JI; ::X' \
;I Bl'SHl!'iG-Throttk Ll',.,.r
1'l TAP f.i. PIN-Bu :itu ni:
2 CLEANING AND INSPECTION jJ 00 DY- rhNlll e
H PLtl(i ,- Aulu. C'h, C"l:ollln,.I
l" hrnughl_,· cl.-a 11 r1ll ml'lal parts 111 I',\; !) :\ll•1nlcl 1 ·1w or Spt~dclene. i :I JET-Pk~ur
K!vw l 1u 1 all JJil_[l:- 1111d ch1rn11els wilh air prrs.~11n•. ln~pel:I houJlng for '?Ii 0 \..-.;~·r.r....:f'llln.:"
durn,q~l-. t'.He:1:1i,· t wtRr . hurrs or ~·arptlge. UO :'\OT CLEA~ '.'\O~ •
\ l ~:T .\ 1. 1.W l'.\l:Ts it~ I',\ 11 ;-.letalclrnt or S1ic:edcll'nt'.
JtU.l~T
2. hutaU well vent }et ( 3_.) ln fuel bowl and t~hten
Wbea ~bU.04 carburetor UM ~ y the 11-hUy, u.ainc Cl61-80 well vent wrench for
r ..-vu-t< Of'da from diau..c:m b ly. 6JAW 1' and -16; Cor 63AW 10, . 11 aod - 12
M<><i.c:u • ~•drivel' LI ua.ed ln place o( tool
Cl6l•&O.
lll!MNT Of OiOU ... IJI IHlAU - MOOW 3. P\&ce nbu wa..hu ( • 7) on a.ccelcra~ aod po..-er
i..MW 14 U.0 "-'W 16 }d (60) LOd lllau.ll Jct ill thrcade<l AD&k puugc
I ~ c:b olL c a.h-.11 p.&dt.ln& (ek ( 63 ) 1.nto co Wl1er • ln bottom o! fuel bowl. ualni a.crc..-drtvcr.
't>o re al I Ml< ol alr .Ul take, then lnatall ch okc 4. Place fiber wub.cr (43) on m&Jn Jct (H) and
b raic:1 et ( 6-4 )., a.cco rcilD I to much mu k.a m ad.e lllata.ll ma.lo Jd ln l&rJe threaded puu.ie in
al time oi dl1-uacmbly, &lld a.u.embl.e bracket 1lde of fud bowl, u.alllg C 161 - l wrcocb for main
~ ( i6) aod lotlwuhen (56 ). }eU th.at a.re uffid with maln Jet adjwtmenl ; aod
'.l . IQ.Mt"t c:boJu aha.rt (36) Ullo choke ah&!t bok:a Cl61 ·82 wreoch for at.a.ndard main )cu.
•11:h 1roovcd c.nd oC a.halt at aide oppo11iebracket., S. Pta.oe nbe.r wauhu (-'8) oo he.x plug (-49) and
tbCD uu.tLlJ borw aboe th.nat wauber (37) Ul lnaL&ll plui to threaded pa11age over accelerallog
1roo~ o( a.h&ll. }et, u1lni • 7/ 16" or a l/2" wrench, a, requlred .
3 . Wltb m&.eh.lned a u ~ ol fuel bowl up a.nd alr 6. lnaL&ll ma.ln Jc( adJu1lmcot aucmbly (46) or hex
Lnti.ke oo oea.r 11de, rolale . aha.rt lo have Oat plui and fiber wuber (45) in threaded pauage
,~e ficlni dowo. I.n.w.rt choke pl.Ate (61) lnto over maln Jet, u1lng a 1/2" or a 5/8" wrench ,
a.lI lnta.k.e aectioo poppet aide flnt and wLtb apring u requlre<l.
of popp,e v aJve [actng down.
7. ln.ataU draw plug1 (52) and (51) ln threade-d
4. Ce.oi.u chor.e pate iD aha!\, cloM: choke aod all&o paaaages at bottom oC air Intake and fuel bowl ,
b o~ w
( 63) LO
/L&~ aod a.ha.ft, thco i.nata.11 three 1<:rew1
lodwubcra (62) looa.c.ly. Tap choke
u1lng n 3/8" wrench.
plat:t ' l~btJy 10 ccnt.u plate aod then Uihten 1<:rcw1 NOTE : Some modela do not use theae pa rt& .
e-venly a..od Qrmly. 8 . Flt formed cod of C 16 l • 121 power Jet wrench
5 . lo,taU covc.r platr gaakct (-41), duat cover pl.ale oo power Jet valve (33 ) and lnalall valve in
( 4 0 ), ~ • ( 38) a.nd loclc-waabcn ( 39) to th nut
bottom o( pump cyll.oder .
..,, ubu aldc of Lir lnta.k.e. 9 . To ln•tAli pump check valve aaaernbly (35 ),
6 . l cu1aU chol,,:e cl&.mp In-er (68) on ,halt with atart check valve Leto counter•bore with amall
,wtvel [aclog bo<ly a.od po1ition lever 10 that opcnJng out aod aUgn valve 10 lhat ll I~ no l
aw Ivel LJ a.ligoe<l with rube bolder u< a.ere,,; when coded at .a.n aogle. For 63A W 14 and• 16 carb u re-
c..bor.e LJ cJoa.ed, then Ugbteo lever aci a.crew (60). lora, l~rt !or med end of C 16 l • 124 ch eel,,: valve
. .. tool lnto .. check ..v..alvc bo<ly a.od drive check valve
lnto count.u•bore with a Ught hammer unlll 11
A.sSUl.1-4.'1' Of CHOlE IN A& INTAKE - MODELS .-trUc~ bottom. For 63AW 10, • 11 and - 12, use
~W 10, bl.AW 11 Qnd 6:J.AW 12. a Oat 1/-4" f.unch aod drive cbe-ck valve aqua rely
lnto channe .
l . Hold tuel bowl a.ncmbly with machlne<i aurta.ce
up a.nd (acing air to take, lna.ert choke ahalt lo NOTE: Top of valve 1hould be Jusl below lop eod
1baft bolea from left aide (threaded end laat) . of channel when ln place.
2. k o.ia~ cholc.e ,ban to have Oa, aide facing down,
l.bu:i l.rueri cbol,,:e plate (30) Leto air Intake, poppet
valve Oral and with 1prl.og o[ popp<l valve facing
down . REPt.ACEMENT OF THlOTTlE SHAFT BUSHINGS
3 . Center choke plate on aha.ft, clo11e choice and NOTE: Do not attcmpto removethrotlli:shaft bushings
a.Jig n bole lD plate with hol~ ln ,ha.ft, then ln1lall unleu ocw bu1hLng1 are available for replacemen t.
..ere,,, (28) and lockwaaben (29) looacly . New buablng1 are undtnize and requ ire ream ing
with a line reamer to ru 11haft properly . Bolh bush in gs
4 T ap cbolc.c plale UghtJy lo center plate and Ugh ten and reamer muat be avaUable to comple1e U1 i s opera 1,on
&-Crew, evenly and firmly. succeu!ully.
S . Pia~ cbolc.t bracket on bracket auembly ,crew l. To remo ve throttle shaft bushing \6) from l.brotLle
aod anacb bracxet 10 air Intake In aame poalUon body, acre-w a taper lap I/ 16" la rger Lhan 1hr o ttle
It wa.1 lD bdore removal. Rc!cr to match marlc1 abaft bole aLtc Into bushlng unlil fLimly at111ed .
m ade at time of dl..ae..ucmbly. theo ln1ert long punch or rod in opposi1e sha f1
6 . H o ld choke In wide op<o poallioo and place choice bole and dr iv e punch againsl end or tcip unt tl
le-vu on 1baft 10 that lug on lever contacta lug buahlng is free uf 1hro1tle body .
on low er tnd of brad.ct. 2. Re~al above uperalion lo re move &e<" ond bush ing
~OTE : Check travel of kvi::r to mal,c.e 1ure choke at opp o & It e a Ide of th rot tJ e body.
..,tlJ op en and cloac hilly . 3 . To lnstall new throttle shaft buihing, place new
7 lolLaU cbolc.e lever nut and l~waahcr and Ughteo buablng on Cl61•72•4 buahing driver wllh taper
&ecurel y end of bushing away from i;h oul der .
3 I nataU ch olc.e 1ha!t bole plug and gux.et at aide 4 . Stan bu11hlng lnlu lihaft hole and drive bu shing
oppoalte cbolc.e lever. In until I! boltomi;, ur;lng a llghl hammer .
5 . Repeat operations 3 and 4 to install second bushing
ln oppo1lte aha ft hole .
ASSE~aLY OF FUEL BOWL - AU MODELS
NOTE: Cl61-72-3 Bu,blng driver is fur 5 / l6"ahan :
Place Ober ..-iuher t 64) on m aln dl1charge Jet C 161-72-4 driver la for 3/8" .hah .
( 65 ) aod Lo11alJ Jet l.n fuel bowl and Lighten
11rmly , ualng Cl61-9 wreocb for 63AW10, -11 6. Line ream the two bushlnisa afler liUembly . ur;ing
and - 12 . and Cl6l-l0 wrench for 63AWl4 CJ6l - 71-3 reamer for 5/16 " sha ft ,iize or
aod • 16 carburctora . Cltil • 71-4 reamer for 3 / 8" shaft w,u .
 ZENITH CARBURETOR RESTOROGRAPH 63, 63M & 263M
SERIES

i l -- 1

y
0
1 -2
KEY
NO . PART NAME

I SC'REW-Bowl to Bod y
2 LOCK WASHER
J SC RF:~ Th rottle · Plate
~ PLATE-Th rottl e
~ SCREW- V acu um Chan nel
6 RUSHING-Th rottle Shatt
l WAS}IER-ShB fl Pll.Ck l ng
8 R.ET All\ ER-Th ro t .Sh . Plti ,
9 SHAFT L: LEVER-Thrott l e
u SPR.ING-Thrt)l.Stop Screw-.
11 SCREW-Throttlf Stop .
12 SCREW-Throt . Lever Clamp
13 LF.VER-Throttle Clamp
14 LEVER-Throttle St rip
1~ SHAFT-Throttle
16 PLUG-Vac,;uum SpB.Ik Channf' l
11 PLUG-Piller .
18 WASHEa--Fllter P lu~
19 SCR.EEN-F'uel F'Uter
Z{) OODY-Unlon
21 WASHE&-Unl o n Rod.v
n NEEDLE-Idle Adjusttn&
23 SP'UNG-ld l P. Adj . Nee<lle
i4 JET-Id l e .
~.,...-<::_27 2~ ll'ASRER-F'uel Va. Iv " Seat
2i VALVE~ SEAT-F'uel
~ 2 8 21 ,\J(LI'.;-F'loa.L
28 F1..OAT
29 GA.SKIT-Bow l t o Body
32 V£NTURS
33 VALVl::-R:l•er Jet
3-4 YENT- W~ l l
l!) VALVE-Pump Cherll
3G Sil AJ-1 -Ch~ e
:n WASHElil-Ch. ~ - Thrust
38 SCIU:...Cover Pa.le
39 LOCK1U.SADl .
40 PLATE-Ch<>lle Sh . Cover ·
63 41 UASKET-Covl!r Plate ·
OOWL-F'ue l
62-\
61 ~
I I
42
~3
44
WASH Ell-Ma.in J i> t
JE'T-M&ln
4~ l 'ASliE~-4.la.in Pa.ss~e P lu e
~ 4-6 PLUG or AOJ.-Ma.ln Je t
41 • ASHE&-P o •er / Acce l. J et
-42 ~ IASJiER-Pu s 4e P lu &
~ PLUG-Pa...ss~e
::i o JET-P o we r &. Acc P.l eru in a
~ I PL U G or YAL\'£-&>w l Df &.l n
H PL UG-I nt u e Dnl n
:)3 W ASRER-Ch .Sh . P~i ina
:)4 B itAc-1( E'T-Choll c
:)~ LOCK I A.BiHEll
~ s.<.:R F: •-Bracket
:)i S('lt£W-Tube Cl a.mp
~8 U: \ .E&~or.e
~9 SCll.£w----(;h.Lever Slfivel
60 SCREW-Ch . Lever Cl~
61 PLATE-Choke
62 ~ WASH Ell
63 SCR£W--Cholle P late
64 WASHE1l-Di~h&1re Jet
l DISASSEMM Y 6~ JET- Dlscha.i1e
bi PUMP PISTON
D lsa .\ semb iy co n s ists o f separat i ng the carburetor lnto t':'-·1> bas i c gro u p6 : t;i • ·.-\SHER-lnld P i ua
fu el b o -.1.·l a n d ai r i ntake - thro tt le body and the Jlsassembly of each of 68 PLUG-F'uP i [r. lPt
lhest' l'(roups. l ' s e exploded illustration · above al\ ,1
guide fur d 1sas:i:t-111bl y t;9 L I )("K If \Sll 1-: ~
a nd rl'il st-emb l_,. ·, 0 S( ' HL-- V 1:-n : :.u ; ::X' l
;I Bl 'SHJ~G-Thro l tl •• L1•,·•• r
12 TAPF:R PIN-Bu~hini:
2 CLEANING AND INSPECTION jJ BO DY- f h rvtlle
;~ PL1 1c; -Aut u . Ch . c-t:annt-'I
niro ugh l~· c le a ,1 r1 ll ml' ial par ts i 11 I',\: 1) \ll'till, 1 111.' o r S pei>dclene .
1
i~ JET-P ic' ~ur
H!u .,., u ut a l l µ,1r ll' n 11d chA 1111els w ith air pressurl' . lnsp ec l hous ing for l Fi 0 \S1,t;F.T-P l 1>n.: 1·
d um a~ v. t' Xl' e:-- :i i n ' \\t:R r. h urrs or \l.' arpc1ge . UO \.;ll T ('1.1•: A:\ \.,' ( l."-:-
\11-: T .\l.l.l t l' . \1: I' ~ it' I' ,\ 11 ;\letalckne or Spcedclent' .
 r l bowl and t~hten
2. hutaU weU ~·cn,t ~l~~~~cin w~~ ven\lwlrea~d _rf~
1 KA.Ullllll'f . UM ~ y the UcbU)' ~,n 63AW 10 . l
63A W '14 and . 16; {or la uaed l~ place of too
:'~ :m~lll
. bUnc carburetor
dwuacmbly. Moddl a ecnwdnvu
c \61 · &O. el,ratini and power
~\'J
~ ~ade<l an&le puM.ge
~=
.uszrr-, .
Of OtOG _,. All IN1AD - MOOllS 3. Place fll>u wuher
UAW IA UC, UAW I• }d (60) &Jl1 t~owl, u1lng .crewdrtver .
1. lsuert choke lhd paduiic fat ( 5-3) ln bottom o et ( -4) and
b<>~ at 1 ~ o{ alr Intake. theD de
4
-4 P\ace11 fiber wubtr (43) ont.hmildn l puuge ln
bracket (·M ). aa::on11ii1 to a:i,&Jch mark.a ma • ,_ aui )et w lar1e rea «i
ln•~ m Cl6l-lwrcAChforlJ"laln
of fuel b~~ u.al1::ig a1n )et a.d)u.atmtnt : a.Pd
at time ol dl11uembly, and -....embw bracket ald.e
ecn-n (6:6) and lockw . .ben (65). th.al ~ u~ w
Jeu m l Jet.a
2 ln.M:r1 cb~c abaft ( 36) l.Dto choke abaft hok:a
Cl61 ·82 wreocll for tt.a.ndard man .

3~) f
• wW:b srooved end of abaft at aldc oppoalte b( ftbcr wuber ( 48) on hex plug (-49) and
then 1n.at.&.ll bone aboc th.nut wuher
sroove of a.ball.
n 5. ~WI plu1 ln threaded pauage over accclera~inJ
}et, ucing a 7/ 16• or a 1;2• wrench , as requ e .
3 Wlth ma:ch.ined aurf.a.ce ol fuel bowl up and al.r 6 lnata.ll ma.in Jet adJu•lmeot auembly ( 46) or hex
· lntike on near aide, rotate aha.It to have Oat . h (45) in t.hreade<l pauage
aide f&clrig down. ln.acn choke plate (61) into
plug and fiber wu er •
over main Jet, u•lng a l 12 or a
5/8" wrench,
alr lnta.lte tectioo poppet alde fl.rat and with aprlng a, required.
o( poppet. v alvc facing down.
7 ln•taU dralo plug, (52) and ( 51 ) In threaded
4. Center choke plate in ahaftth, clo~~-cht ollkthe aod.....ar~ewo, . paa.agea at bottom of ai r In take and fuel bow l.
ho~ lo /UL~ and a.haft, en LU.- a ree - ualng a 3/ s• wrench.
(63) a.n lod:wuben (62) looaely . Tap choke
plate lightly to center plate and then tighten &erel!l's NOTE : Some models do not use these parts .
evenly a.nd firmly. Flt formed end of C 161 - 12 1 power Jet w rench
5 Ioatall cover plate gaaket ( 4 1 ), duat cover pla~ B. 00 power jet valve (33) and Install val v e In
· (40), .crew, (38) a.nd loclcwaaben (39) to thruat bottom of pump cylinder .
wubu aide o( a.lr lntalte. 9 To lnatall pump check valve assembly ( 35 ),
6. hutall choke clamp lever (58) on abaft wlth · »tart check valve l.nto couoter · bore with small
awtvel facing body and poaltion lever ao that operung out and all_gn valve ao that It Is not
nrlvel La · allgned w1th tube bolder kt .crew when cocked at a.n angle. For63AW14and• 16carbure·
choke La clokd, then tlgbteo lever •et tcrew (60). ton, !~rt formed cod of C 16 l - 124 check valve
. . ' . , ~

. too l i.nto, .chtck.. v.alve bo4y and drive check valve

lnto couoter - b ore with a lig h t ham mer unill ll
ASSEM&LY OF CHOKE IN A■ INTAKE - MODELS
63AW 10, UAW 11 ond 63.AW 12. .atrikea bo tt om . For 63A W 10 , - 1 1 and · 12 , use
a Oat 1/4• f.unch and dr ive cb eck valv e aquare ly
l. Hold fuel bowl auembly with machined 1urface into channe .
up a.nd facing air intake, lnaert choke ahaft lo NOTE: Top of valve ahould be Jus t below top eod
abaft holea from left aide (threaded end laat). of channel when l.o place.
2. Rota~ choke abaft to have Da, aide facing down,
lhtn lnaert cbolte plate (30) ioto air Intake, poppet
valve .firat and with apring of poppet valve facing
down . ·
REPLACEMENT OF THIOTTLE SHAFT BUSHINGS
3 . Cent.er choice plate on shaft, close choice and
align bole lo plate with boles In abaft, then install NOTE : Do not attemp to remove thrott l~ shaft bush ings
scr~a (28) aod lodcwaabere (29) looaely . unless oew buahlngs are a v ailab le for replacemen t.
New busblnga are undtrsi.ze an d r equ ire ream ing
4 . Tap choice plate ~bUy to center plate and Ugh ten with a line reamer to ru shaft properly . Both bush ings
r.crewa evenly and firmly.
and reamer must be avaUa ble to compl e le this opera lion
5. Place choke bracket on bracket assembly screw succeufully .
aod atta_c b bracket to air Intake In aame pos!Lion I. To remo v e t.hrotUe shaft bush ing t 6 ) from throttle
It •u 1.n bdore removal. Refer to match marks body , screw a taper tap 1/ 16" lar g er than throt tl e
made at _tlm e of dJ.aauem bly .
shaft bole 1i.ze Into bushing unt il fLim ly sea ted ,
6. Hold choke In wide o~o poaltioo aod place choke then Insert Jong punch o r ro d in o ppos ite s h a ft
lever on abaft 10 that lug on lever contacts lug bole and dr iv e punch agai nst end of l a p u n!il
oo lower end of bracket. bu1h1ng is fr ee vf thr ot t le bod y .
NOTE : Check travel of lev~r to make sure choke 2. Repeat abovl:! <1pe rat io n to r emove SC<'ond b u s hi ng
will open aod clo1e fully . at oppos ite aide of throttle bod y .
7. l01taU choke lever out and lod(waaber and tighten 3 . To install new throttle shaft bus hi ng, p lace new
securely . bushing on C 161 • 72 • 4 buah in g dr iv er with taper
end of bushing away from should e r .
8. lnatall choke •halt hole plug and gaaket at aide
opposlt~ choke lever. 4. Stan bushing Int o shaft hole an d d r ive bush ing
In unt il !I bottoms , us ing a lig h t ha mm er .
ASSEM&LY OF ,:UEL BOWL - AU MODELS 5 . Repeat operat ions 3 and 4 10 insta ll second bus hi ng
In oppos it e shaft ho le .
1. Place nber waaher { 64) on m aln d ischarge jet
( 65 ) and lnatalJ Jet 1n fuel bowl and tighten NOTE: Cl6l-72 - 3 Buabing dr iv er is fu r 5fl 6"shafl ;
Orm ly, u1lng Cl61 - 9 wrench for 63AWI0 , - lJ C 161 - 7 2 -4 dr iv er is for 3 / 8" sha f1.
and ·12 ; and Cl61 - 10 wrench for 63AWJ4 6 . Llne ream lhe two bush ings after assembl y, us ing
a c d • 16 ca r b u ret o ra . C l 6 I • 7 l • 3 ream e r f o r 5 / l 6 · · s h a f I s iz e o r
Clt:il - 71 -4 ream 1: r fo r 3 / 8" s h af1 siu .
ASS~Y OF THIOTTU IOOY · ---------------------. · 30.02
l. Auemble lhrottie ,h&!l p&,ekl..p.c (7) .ln open Jki.e
ol reul.oer ( 3) and pa.cc complded a.uanbly. on
C 161 • 72 -3 bu,hin, d.rtvu (uMd with 6/ 16.. th&f't)
or C 161 • 72 ·-' ··b\.Ublnl driver (~Md · w,Ub -~/S-
ah,J\) with packini Caclzu
... .1m&ll cnd :of drtver.
ltuc.rt ,mall c.nd o! drtvu Into tlu'ottlc ,ba.lt °Qu•h~-
lng. Sta.rt reta.ln~r lnlocouot.er~borco!body ,ind
~btly drive re(alner Lnto body until Ou,b _wlth
m achlne<! ,uriacr. ·

NOTE: Packing reiainer m.u,t. · be n1.ub 9r, ,UihUy

below mac.hlried 1urface to avoid ,trUdrii; throttle
ltver .

i. Repeat above operation to lnataU 1e<:ond pacldng

and retainer In oppoalte ahaft hole.
3 . lnslall throttle ,haf1 and atop lever auembly
( 9) io Lhrottle body and position according to
match marks made at time of dlaauembly.
4 . ln&erl Lhrottle plate (4) In throttle aba!t In aame
position it waa In before dl,auembly. Center
plate and then rotate ahaH (counter-clockwlseJ
to closed po,ition. Hold throttle plate clo,ed a -n
,tart screws (3 J Into shaft loo,cly. Tap plate
lightly and then tighten »crews.

NOT I:: : Do n,,t attempt to rivet threaded end of throttle

plait· ,crewa .
5 . ln,Lall throttle clamp lever ( 13) and poaltlon
levtr according to malch mark• madt: al time
of dlaauembly . 15. To lnaure correct fuel level In noat chamber,
6 . On models which Include throttle lever buahln.g check dlatance "1\" Crom top of noat.a to ma·cblne<!
( 7 I), lnalall lever bu1hl.ng and u~<:un wllh taper aurlaa (without gaalcet ). Thia dlmen,lon ahould
pln ( 72 ). \. be aa follow,:
7 . On models which Include Ooatlng lever, position Carburetor Model Dlmenalon "A"
lcve-r on shaft and tighten lever clamp acrew. 63AW 10 l · 5/ 8"
8. On 63A W 14 and • 16 Modela, lmtall pickup 63AW 11 1 • I 9/ 3 2"
tube jet (75) in threaded angle pauage of throttle 63.AW 12 l • 19/32"
body near mourillng 'Oange. 63A \,\.' 14 2 · I/ 64 •
63AW 16 2 · 1/64.
9 . lnrndl idle adjusllng needle (22) and spring
( 23) in threaded pauage on aide of throttle body. To Increase or de<:rease dlatance between top
Turn idle needle In llghtly against ILi Jeat, then of noat bo·dlea and machined surface, uae long
back o u I needle 1 • l / 4 turn, aa a prellmln ary noae plier• and bend lever close to noal body.
adju slmen1. NOTE : Do not bend, twlat or apply presaure on
10 . ff channel plugs (44) and (16) were removed, the Ooat bodies . The Ooat bodies when viewed Crom
replti.ce plugs, using 7 / 16· wrench . the free end of bodlea mu,t be centered and at right
angles to the machined aurface and mu1t move Cre-ely
11 . Insert venturi assembly (32) In thr91tle body, on the noat axle.
large opening end rtnt. Rots.le venturi to align
screw pole · wit.h hole In lhrottle body. Install 16. Install vacuum piston auembly t66) in vacuum
locating screw (70) and lockwasher (69) and cylinder In throttle body. Presa retainer inlo re-cei•
tighten screw . · of body with Oat side of ,crewdri\'tir . Check for
free movement of piston In cylinder .
12 . Install idle jel ( 24) 1,, counter• bored hole ln
machined surface near vrnturi, uain·g am all acrew-
driva to tigh1en jet.
13. Install fuel valve seal (26J and Ober washer (25),
uaing a 5/8" socket wrench !or Models 63AW14,
- 16 and Cl61-8.S wrench !or Models 63AW10,
• 11 and • 12 .

NOTE : Be sure correct Ober waaher la uaed. Fiber

wuher 1'56 • 67 (.065" thick) Is used with C85-77
Ooat; fiber washer T 56 • 10 ( .040" thick) li uaed with NOTE: lf pum,p piston should be dlsauembled, mak_e
C85-83 noat. · sure platon I• ·rcauembled on guide rod wllh pl.aton
In aame groove aa when removed, ae-e Uluatratlon,
14 . lorn1U fuel valve needle . ( 26 l in seat. Poaltlon above. for relationship of pump parts. Thre-e groove~
noal a8aembly (28) in hinge br.acket and Insert are provided ln gulde rod to permit changing pump
noat axle ( 27) through hln~e bracket and Ooat atrokc. F.or full slrokc, auemble 1101 In center of
lever bushing from side oppoaite alotted end or piston in uppermoal groove o( guide rod: for three.
bf brackel. Then puah axle through ,lotted end quarter ,troke, ln center groove; (or one. half sirok(',
of brackt'I, u»lng hand le end of acrewdriver. In bottom groon.
17 . rlace1hru11le body ga~kel 1291 on rnal'hint'd \'1ti) and ~askt-1 (671 in opp~isite end of fud
,udace of 1hrot1le bod,v . passage.
:'\()TE: Some o3A\\' IU. • 11 and • I '2 ~tudeis usi:
ASSEMfHY OF THROTTLE ANO FUEL BOWL 5O01ES 11 f\.lter head and nltt''r 1:lemenl iii plfH·e of tht:H' paris .
I . 1'1 t11 ·e th rut tie body un fuel bowl, being careful Auembie elt'ment to head with fingers onl_y 11 nu
not tu damage nvals 1.H \'at'uurn piston asaembly. install in fuel Inlet p1usage on these models . ·
Align hvle) i11 lhrottle body and ~asket with hoir:i
111 fuel buwl 11nci inst11ll thruttlt: body aasembly ~ - Hold throttle clo:sed and turn thruttle ::1tup screw
scrnq l I 1 ,rnd lockwashf;'rs (:2 l (four or six, ( 1 1 ) in u n t i I it ) u st co n l a c ts s I o p u n I h rot t I c b o d y ;
a~ requirt'ci). Ti ~hten scrC'ws uniformly and then turn $.l'rew 1:--...; 1 · 1/2 additional turns as
se~·u rely . a preliminary idle speed adjustment .
'2 . lns1 al l . /uel fil1er b11ct .v (:20). screen 119) twu fiber NOT!-: : If carburetor is to bt- used with speed governor
....-a~hcrs (11:l) and \:21) and filta plug \17) in installt'<.J between tht: carburetor and ' manifold, be
thrc-:.ided passage in throttle body uf ti:3A\\' 1~ sure \'acuurn channel screw(Silsit1pl<1cein carburetor
,rn d o}A\\' 16 carburetor:. .· lnalall fuel inlet plug nangc.

- - - - ---- - ---- . ... ....... - ----·-·

 IN STRUCTION SHEET
ZENITH CARBURETOR SERIES - 61-62-67-68-161-267
GENERAL EXPLODED VIEW
THE GENERAL DESIGN AND PARTS SHOWN WILL VARY TO DISASSEMBLY
INDIVIDUAL UNITS OJVERED ON THIS INSTRUCTION SHEET
USE EXPLODED VIEW AS A GUIDE, THE NUMERICAL SEQU ENCE MAY GEN ERALL '
BE FOLLOWED TO DISASSEMBLE UN IT FAR ENOUGH TO PERMIT CLEA N ING AN!
INSPECTION, NOTE: BEF'ORE RE,-OVING THROTTLE VALVE (18) MA.KE A SCRIBI
MARK ON VALVE AND SURFACE OF FLANGE, ON SOME SERIES CARBURETORS I"
IS NECESSARY TO FILE OFF REVETED OR PEENED END OF THROTTLE VAL VE SCREl,f
(l7) FLUSH W'ITH THROTTLE SHAFT BEFORE REMOVING,
18

~
1d ~
-_Jv- ,-Al REF',
00,
NOMENCLATURE

REF,
NO,

r l,

2.
SCREW !. LOCl<WASHER ( 4 ) - BOWL
COVER
BOWL CDVER ASSEMBLY
18.
19,
20,
VALVE. TiiROTTLE
THROITLE SHAFT I, LE VER ASSY.
SCREW . THROTTLE S1'0P
I 3. SCREW!.L.OCKWASHER(SERIES 62) 21, RETAINER • THROTTLE S HAFT SEAl

I
I 21\®
L--@-0 .
22 4,
5,
6,
7.
8.
VENTURI
VENTURI
GI\S KE T - BOWL COVER
PIN-FLOAT LEVER
F'LOAT !. LEVER ASSEMBLY
NEEDLE, SEAT!. GASKET ASSY.
22,
23,
SEAL • THROTTLE SHAFT
PLUG. THROTTLE SHAFT HOLE
24. JET. \.£LL VENT
25. NOZZLE. MAI N
25A , NOZZLE(SERIES 07-267 ) - MAIN
26. GASKET. MAIN OOZZLE
9. JET. IDLE 26A,GASKET(SE?IES 67-267 ) MAIN
10. JET(SERIES 62) -ECONOMIZER NOZZLE
11. GI\SKET(SERIES 62) - ECONOMIZER 27, PLu::; - MAIN PASS AGE
J ET 27A.MAIN J ET ADJUSTMENT
12, NEEDLE • IDLE ADJUSTING 28, GI\SKET - MAIN PASSAGE PLu::; OR
13. SPRING. IDLE ADJUSTING NEEDLE MAIN JET ADJUSTMEN1
14. SCREEN !. FITTING. FILTER 2 9, JET. MAIN
15. GASKET. SCREEN !. FITTING 30, GASKET • MAIN J ET
16. PLu::;-FUEL I NLET 31 . PLUG. CHOKE SHAFT HOLE
17 . SCREW I, LOCKWASHER ( 2 ) • 32, GASKET - CHOKE SHAFT PLUG
THRO TTLE VALVE 33, F'LOAT BOWL ASSEMBLY

CL EAN ING
8 C LEANING MUST BE DONE Win-t CARBURETOR DISASSEMBLED. SOAK PI\RTS LONG
ENOt.XmTOSOFTEN AND REMOVE ALL FOREIGN MATERIAL. USE (l)ACARBUR ETO R
CLEANI NG SOL VEN T, (2) LACQU ER THINNER, OR (3) DENATURED ALCOHOL. !'<AKE
CERTAIN THE THROTTLE BORE IS FREE OF ALL CARBON AND VARNI S H DEPOSITS.
RINSE OFF IN SUITA BL E SOLVENT, BL.OW OUT ALL PASSAGES IN CAST ING W!TH
COMPRESSED AIR AND CHECK CAREFULLY TO INSURE THOROUGH CLEANING Of" OB-
SCURE AREAS , CAUTION, DO NOT SOAK MAIN JET ADJUSTMENT (27A) OR RUBBE R
6 PARTS IN CLEANING SOLVENT,

~ REASSEMBLY
REASS EMBLE IN REVERSE ORDER Or DISASSEMBLY. NOTE SPECII\L INSTRLICT!O NS .

SPECIAL INSTRUCTIONS
MAIN JETADJUSTMENT INSTALLATION (27A) • BACKOUTNEEDL.E SEVERAL nJR N~
BEPORE TIGHTENING ASSEMBLE IN CARBURETOR, THEN TURN IN LIGHTLY UNTIL
SEATED AND BACK OUT 2 TURNS.

THROTTLE SI-IAPT SEAL INSTALLATION • INSTAL.L NEOPRENE SEAL (Z2) WITH

SEAL.ING EDGES ro Tl-IE OUTSIDE, COVER WITH F'LAT WASHER (21) AND STAKE
IN PLACE ,

11-IROTTLE VALVE INSTALLATION • INSTAL.L VALVE (1B) WITH SCRIBE MARKS

ALIGNED, TAP LIGHTI.Y TO CENTER IN THROTn.E BORE. TIGHTEN SCREWS SE .
CURELY. I-MERE NECESSARY, PEEN END OP SCREWS, THROTTLE HELD CLOSED,
TURN THROTn.E STOP SCR EW (20) IN UNTIL IT JUST CONTACTS STOP PIN, THE !\
TURN SCREW IN l 1/2 ADDITIONAL TURNS,

IDLE NEED LE INSTALLATION • TURN NEEDLE (12) I N LIGH TLY 'JNTI L SEATED.
THEN BACK OUT l 1 /4 TURNS,

CAUTION: DO NOT EXERT

PRESSURE ON RE.SILIHIT
NEEDLE VALVE

SERIES -61-67 - 68-161-267(1 5 /32")

SERIES -62(1 39/64")

FLOAT LEVEL I\DJ1.JS TMENT

WITI-1 80WL COVER INVERTED, MEASURE PROM MACHINED SUR PACE OP 80WL COVER
(NO GASKET) TO TOP OF' EACH PLOAT PONTOON, TO ADJUST BENO FLOAT L.EVER
CLOSE TO F'LOAT BODY. NOTE: WHEN VIEWED F'ROM FREE END, THE Pl.OAT PON -
TOONS MUST BE CENTERED AND AT RIGHT ANGL.ES TO THE MACHI NED SURF ACE OF'
BOWL COVER AND MOVE FREEL Y ON THE PLOAT PIN.

VENTURI INSTAl.l.ATION • INSTALL LARGE OPENING END OF VENTURI (4) INTO

THROTTLE BORE AND POSITION VENTURI SO THAT MACHINED F'LAT WILL BE ro .
WARD F'UEL BOIYI.. \o/HEN ASSE.MBLED, SOME SERIES USE A GUIDE NOTCH OR SCREw
TO HOLD VENT\JRI IN PROPER POSITION,

IDLE ADJUSTMENT . ENGINE AT OPERATING TEMPERATURE, CHOKE VALVE CDM-

PLETELY OPEN, ADJUST IDLE SCREW UNTI L ENGINE RUNS 51'1:X)THl.Y WITH IDLE
STOP SCREW SET AT PROPER IDLE R.P.M.