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Installing 1998 Johnson 200 Carb Kits

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Ricklong

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I have fuel coming out of the lowest carburetor on the port side. How hard is it to install 6 carburetor kits on a 1998 Johnson 200 Ocean Runner? Are any special tools needed to rebuild or sync the carbs?
 
Boobie said:
Get a factory service manual. Tells all.
Click to expand...

I have a factory service manual at home but I am away for Memorial Day. Had to be towed back to the boat ramp a few hours ago. If it doesn't sound too difficult I am ordering 6 - 0437327 - carburetor Repair Kits with floats on the internet today. Instead of waiting until I get home and read the service manual. That way I can start work on the carbs a couple days sooner. ​
 
You'll need a screwdriver that fits in the lower drain hole and long enough to reach the main jet if you want to remove and clean it. The rest is very straight forward. The kits I got came with an extra flat washer that I didn't need, and the float needle valves were all metal, not rubber tipped like the ones I replaced. Worked fine though. The spaghetti gasket that goes between the carb and the throttle body is a pain; I've read where some people use grease to hold it in the groove during assembly. If your motor has been running well I wouldn't touch the idle mix screws, just put the carbs back on the throttle bodies. Shouldn't have to do any other adjustment to sync them. If the TB's are removed, there is a procedure in the manual for syncing them.
 
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Kinda a double post here, but a couple of things not covered before. Idle is controlled by idle timing. That is unless someone has really screwed up the low speed mixture needles. If the motor is out of sync (butterflies cracked) and someone tries to cover that up by richen the carbs too much idle speed will suffer. Motor may still spit lean?
The plastic (Minlon) carbs do not take the plastic gasket under the needle seat. Only the aluminum body carbs do. Same needle & seat assy. so they have to send it with it.
On the o-ring seal on the back of the carb bodies. If you will put a little grease in your hands & rub the o-rings in your hands then they will stay in the grooves until you mount the bodies. Sometimes just a little stretch of the big circle will help before you put the grease on.
 
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