1988 Johnson Evinrude 40HP Outboard Carburetor Rebuild Part 1

These carburetors are fairly easy to rebuild. I used the OMC service manual as a guide to rebuild this carburetor. There are a few things that the manual calls for that have suitable, affordable substitutes. Two of these are the OMC screw lock and the OMC Ultra Lock. You can use Loctite blue for the OMC Screw Lock and LocTite Red for the OMC Ultra Lock.Carburetor cleaning is an important part of this rebuild, I used carburetor cleaner from the auto parts store.
Here's an affiliate link to the kit I used to rebuild the carbs:
amzn.to/2nqUjk6
For a collection of the tools and materials we use, Make sure to Visit our Amazon Affiliate Storefront:
www.amazon.com/shop/josesextr...
A Quick disclaimer, I am not an outboard technician. I do however do my homework and consult with experts when necessary before doing much of the work I do on outboards. Last of all, I get a service manual on the outboards I work on and a thoroughly familiarize myself on the area I am going to work on.
Read the entire rebuild at extremediy.org/1988-40hp-evin...

[@artslade125]

@ Jose’s extreme DIY, when u replace any of the Jets after cleaning do u have to adjust so many turns in or out ?

[@ExtremeDIYGuy]

These carbs don't have an idle mix adjustment so just gently seat the jets.

[@katiemccarthy4570]

I saw that you poured alcohol to check for leaks in the emulsion pick up tube. Where exactly did you put the locktite?

[@ExtremeDIYGuy]

Inside the carb where the emulsion pick up tube comes out of the float area. 7:55 in the video is a good reference to see where I applied the red loctite. Out it on both top and bottom sides of the pickup tube to ensure a good seal. Thanks for watching!

[@katiemccarthy4570]

Thanks you so much for the help and the reply! I read your write up on this as well and just wanted to make sure.

[@ExtremeDIYGuy]

Your welcome! I'm glad I could help!

[@ExtremeDIYGuy]

@billywilliamjr I would back out the screw one whole turn and start from there

[@richardhartman4774]

mine doesn't have float needle clip, my needle isnt designed for one. It matches the manual. Odd though. Is this float height somewhat universal?

[@ExtremeDIYGuy]

I think that the float height is probably universal. The key thing is that the needle shuts the gas flow when the bowl is full so it would make sense to have the float height slightly elevated so you don't flood the engine.

[@lmt-adventures620]

My tiny flat idle screw in n front of the carb right above the intake hole comes lose all the time from two full turns out at tight position (the sweet spot for my motor) so it keeps dying and won’t start until I turn it back. Is there a retainer for these things? I don’t see one on yours and so many others online so I’m confused why mine won’t stay in place at the sweet spot for the motor.

[@ExtremeDIYGuy]

If it's the same carb as mine it should be seated all the way in, there's no fuel idle adjustment on mine. Check on marine engine web site. The detailed drawings there might show you if there's a missing part.

[@lmt-adventures620]

@@ExtremeDIYGuy Thanks, I’ll check online hopefully my serial number is still visible. Everything looks the same as yours except that little screw yours is a long one that “seats all the way” mine is a tiny flat screw that needs to be two turns out anywhere else motor won’t even start (that’s her sweet spot) but screw won’t stay in place. I have no other adjustment screw on the carb so this is probably the slow speed carb adjustment which makes sense why it needs to be turned to run. My issue I have to solve is whether a retaining part is missing or idk.

[@brycemccurdy1888]

Would this be relatively the same as a 25hrs motor

[@ExtremeDIYGuy]

I believe so, should be pretty close if not identical.

[@bertrenolds5]

I rebuilt my carbs and I'm chasing an issue where it seems like I have tons of fuel in my carbs. Wonder if I need to red locktite around my emultion tubes? How long do you let the red locktite sit as well? Could an incorrectly set float cause lots of fuel to sit in the carb intake infront of the throttle plate? Basically my engine idles fine but when I put it in gear and apply load it basically slowly dies. I can rev it up in neutral though. Tons of fuel on my plugs and in the tb infront of the plate. Im replacing my reeds as well.

[@ExtremeDIYGuy]

Sounds like the float needs adjusting, excess fuel is usually the float or the needle valve. The red loctite should cure in an hour or less but probably wont help with this problem. It sounds like the motor is starved for fuel when under load. Not sure if you have done this yet but a complete cleaning or rebuild of the carbs will probably help. Also, don't forget to check the fuel tank and make sure it is venting.

[@bertrenolds5]

@@ExtremeDIYGuy excellent suggestions. I didn't have the float guage but I ordered one. I did rebuild them but didn't have the guage. I will make sure the tank is venting. I have tons of fuel on my plugs when it's dying. I think it's maybe the floats dumping too much fuel. I got new reeds just incase as well. Fuel is litterly shooting out of my carbs out of the intake.

[@ExtremeDIYGuy]

@@bertrenolds5 Yeah, that sounds like a bit too much fuel is getting into the carb. This may be a stupid question, but if this is a Johnson or Evinrude, is the primer solenoid in the wrong position? That would saturate the engine with fuel.

[@bertrenolds5]

@@ExtremeDIYGuy watched your video, I was closed. I also pressure tested it and it's holding closed so not the issue. Replacing reeds and resetting floats with a guage.

[@ExtremeDIYGuy]

The red lever should be pointing forward under normal use. I did a short video on that kzbin.info/www/bejne/nWmpdH99m6uhgJY

[@cmikres]

What carb rebuild kit did you use?? Part # or description. Thanks.

[@ExtremeDIYGuy]

It's in the description but here is the affiliate link to the kits I used. amzn.to/2nqUjk6

[@lindachaffins4504]

What's with the music

[@ExtremeDIYGuy]

That was one of my earlier youtube videos, I've since changed the formats I use

[@QwkDraw]

Really hated the music.

[@ExtremeDIYGuy]

Yeah, me too. That's one of my earlier videos, I stopped adding music to them

[@tadpolebo]

Good video, but why with the stupid music?

[@ExtremeDIYGuy]

Yeah I don't put music in videos anymore

[@davidpalmer3015]

Fast motion how-to videos without narration have to be one of the most annoying things on KZbin

[@ExtremeDIYGuy]

Agreed, which is why I have changed my production style over the years

[@davidpalmer3015]

Yessir I see that now, and also I changed the playback speed which helps. I have an early 90’s 40hp Johnson that I need to try and get running. Thanks for the courtesy of a reply and apologies for my complaining 😅👍🏻