2003 25 hp 2 stroke mercury will not start without shot of gas into carburetor

[gordondeese]

Generally, I am having a major concern with my manual start 2003 25 mercury 2 stroke outboard. After basically installing the 1395-8237072 MERCURY MARINE CARB REPAIR KIT, the motor will not start without a shot of premixed gas into the carb. I have removed the carb (numerous times) and verified that all passages from primer to the face of the carb are clear. However, after reading a post of June, 2017 post, I am convinced that the brass insert has an orifice in it that allows a shot of gas from the action of the primer into the intake is restricted. See Flyscott's post of June 22nd, 2017, picture #3 for reference. Sadly, I am at an impasse short of carrying it to a local dealer/repair facility and a wait of about 3 weeks. Can Flyscott or anyone else share some insight on this orifice, should it have any opening in it? If so, how big?
PS: My eyesight is not what it use to be and am having trouble seeing any opening and dare not poke or stick a wire in any of this openings.

Thank

 

[flyingscott]

Make sure you used the correct base gasket. Are all the plastic parts on correctly that primer lever can slide over the knob assembly and won;t work. Before you take it apart fill the carb with gas and push the button you should see a spray. And If you take the carb apart again spray carb cleaner through the primer passages That orifice from the float bowl to the primer is only a check valve. VERY RARE for those to fail.

 

[gordondeese]

Thanks, will try your suggestion

 

[gordondeese]

I have been distracted with other projects for the last few days so I am back to the Mercury. I have examined the carburetor in great detail, making sure that all passages are clear, all parts are on correctly. I filled the carburetor with fuel and actuated the primer by hand, noted a squat of fuel coming out the face of the carburetor that mates up to the intake. I then remounted the carburetor and now cannot get the motor to run but on the top cylinder. I tried spraying fuel into the carburetor while it was running, but no change in getting the bottom cylinder to fire. I shut the motor off as it was making such a racket. I then removed the two new s/plugs I had used and found that the top plug was obviously firing with black substance and a tad wet and found that bottom plug to be clean (no sights of firing) with a tad of fluid on it. May have been the spray of fuel I introduced into the carburetor to try getting bottom cylinder to fire. I then attempted to see if plugs out of motor were firing. Both had fire, but not sure if bottom is producing enough to fire cylinder.
Originally, could not get motor to start without shot of fuel into carburetor after which it would run fine. Now, almost impossible to start with only one cylinder working. I have gone from bad to worse. Any help getting back on course would be sincerely appreciated!

 

[flyingscott]

Spark needs to jump 7/16" air gap. If you took the carb apart did you reassemble correctly.. Is the primer assembly assembled correctly? I would revisit your carb work.

 

[gordondeese]

ok, will look further into carb.

Thanks