1989 Mercury 2 Stroke Outboard 25HP - Gas Flooding Issue (video)

PAR02

Recruit
Joined
Jul 17, 2014
Messages
2
I just purchased my first boat about 3 months ago. It has an extremely clean Mercury 2 Stroke 25hp outboard on it and I have taken it out about a dozen times since I have owned it w/out an issue.

**Disclaimer**
I am not a mechanic. I have never successfully worked on an engine other than to change the oil and help someone else who knew what they were doing.

Yesterday, I took it the boat out and "primed" it with 2 pumps of gas and I noticed some gas leaking from the front of the motor. I had thought for some reason I had flooded it. I waited a bit and started it. It started, idled a bit but then all of a sudden stopped running and again, I noticed the trickled of gas out the front of the engine.. I waited a bit longer, it started, idled a bit and stopped running with a little bit of gas leaking. This happened about 4 times before I took the gas line off and started it again.

When I took the gas line off the motor it ran fine... up until it ran out of gas that was in the filter. Actually that is not true, it ran fine until it ran out of gas that was still present in the carburetor and there was no pressure to get the gas from the filter into the carb. Pressing on the little gas pin where the gas line connects to the motor added the necessary pressure in the system to send the gas from the filter into the carb. Doing this, the motor ran fine until it ran out of gas.

I then put the gas line back on, started it up and once again the same thing happened. It ran fine for a little bit then stopped and leaked a little gas. I called my local boat shop and they said it might be the needle pin float stuck. Well I had no clue what that was and searched on the internet a bit and got a manual for my specific engine. After reading a bit, I found out my engine has a Walbro WM Carburetor Round Bowl - Double Float with Integral Fuel Pump. None of that makes any sense to me but after reading up I found that it did indeed have a float and a pin and so I proceeded to take the carburetor about to see if it was stuck.

Alas, it was not. I put everything back together exactly the way the manual states. I hooked everything back together, started it up and the exact same thing occurred. It would idle a bit and then stop with a little gas coming out of the carburetor.

The following video shows this in action. Basically, what you see in the video is the motor running just fine w/out the gas line attached. The motor is using the fuel it has in the filter. Once I hear it start to run out of gas I immediately plug in the fuel line and you can literally see the gas come bubbling up from inside the carburetor.

I looked at the Inlet Needle and its in perfect shape. The float is in good shape as well. Everything looks good... but man its flooding like a tsunami.

Any ideas?

Thanks!

PAR
 

PAR02

Recruit
Joined
Jul 17, 2014
Messages
2
Whelp, I figured this one out by taking it into an actual Mercury mechanic.

So the issue was (and he has only seen it twice before in his 40 years of Mercury experience) the float itself had gas in it that was keeping it from locking the needle into position.

Apparently after 25 years of usage, somehow the gas, oil, gas + oil or some other molecular subset of the gas mixture had leaked through the plastic in the float and collected inside it. When I had first taken the carburetor apart I saw the fluid in the float and could not see any crack or hole or anything that would suggest it was supposed to be hollow. I thought it was deliberately filled with a liquid to keep it buoyant at a specific height (i.e. tuned that way).

Even looking at the old float now, I see absolutely no cracks or anything that could have allowed gas to leak into it.

So, note to self, floats must be hollow!

Crazy eh?

PAR
 
Top