[Bullzeye]

Hello guys, I need help. Sorry for this long post.

I'm fortunate enough to have a great father-in-law... who lets me work on his outboard motor Unfortunatly I don't know a whole lot about them.

The senario:
The motor (1988 Yamaha 25hp model 25SG) has not been used in 2 years. He went to start it and......you guessed it. It wouldn't start. He called me to come take a look.

I pulled the plugs, cleaned them off with carb cleaner and checked for fire. All Good.

I hooked up my new Yamaha fuel tank and hose with fresh fuel to his motor and primed the carbs full of fresh fuel. While doing this the top carb started over flowing fuel out of the top mixing cover. ** What does this mean? **

I started pulling and it cranked up on the 4th pull! I mixed up a strong dose of ring free in the fuel and let it run for about an hour.

After talking to a mechanic about the fuel pouring out of the top, he said it sounded like they needed to be cleaned.

I pulled both carbs off (broke the nozzle off the fuel pump) and one at a time took them apart and sprayed carb cleaner through all the holes. After taking out the main jet, I could see the main nozzle but could not figure how it came out. No slot for a screw driver. Can't get a wrench down there? ** How do they come out? **They did not get taken out this time. I did find the needle stuck in the bottom carb.

I left all the parts sitting in carb cleaner for several days before blowing everything out and re-assembling.

I installed a new fuel pump body to replace the one I broke, it did not come with new diaphrams or gaskets so I used the old ones. I also replaced the spark plugs, fuel filter and fuel lines.

This time I used the father-in-laws old tank with fresh fuel. I primmed it up (fuel still overflowing from the top mixing cover) and it started up on the 1st pull. However, it barley stayed running, like it was starving for fuel. After it shut off, I started it a few more times. Each time it ran for a shorter duration and it was harder to get started.

I'm ready for round 2, but I'm asking for help this time.

Do I need to get the rebuild kits for both carbs?
How do the main nozzles come out?
Should I replace the gaskets and diaphram in the fuel pump?
Could his old tank be the problem? It ran using my tank, not running using his tank, both have fresh fuel now.

Thanks

[waffles1]

Hopefully you didn't soak the gaskets and diaphragms of the internals of the carbs in the cleaner or sprayed them with the cleaner. It will deform them. I have a Suzuki and the carbs have an overflow if you pump the carbs completely full of gas. They are designed that way. Are you sure your motor isn't doing the same? Did you adjust the jets according to specs when you put them back in? The rebuild kits are usaully low cost and worth the money. If you do not have a repair manual for this motor that is also worth every penny. After you have ran this for a bit the plugs should be dry and tan and not dark and oily. But you do want to make sure you see a little oil and you are not running lean. Good luck.

[Bullzeye]

OOPS! I soaked everything in carb cleaner. Including the fuel pump assembly. Looks like I will get the carb rebuild kits and a fuel pump gasket/diaphram kit.

I picked up a Yamaha repair manual today. It tells you on every page: "Never dip rubber or plastic parts in carurator cleaner. These parts should only be cleaned in solvent and then blown dry with compressed air." What kind of solvent do you use to clean the plastic and rubber parts with?

My answer to "How do you remove the main nozzle." I found this in the repair manual. "Invert the mixing chamber and shake it. The main nozzle should fall free from the turret."

I'm learning the hard way, but I'm learning. Getting ready to order the parts.

Thanks for the help so far waffle. I wish I had researched before starting the work. Hind sight....

[Bullzeye]

I just ordered all the parts. Hopefully they come in before the weekend.