So got the o-ring on Thursday and siphoned all the remaining fuel Friday. Yesterday I put 24 gallons of ethanol free 87 octane and a bottle of Sea Foam. Boat idled fine at the dock.
Started it today and warmed it up then headed out. Ran good through the no wake, got up on plane, then about 1/4 to 1/2 mile later it started to sputter. I backed it down and turned around. It was running about 2500 RPM but sputtering. It did take off once then start sputtering again. I tried going WOT and it bogged worse. It seemed to get slightly better as I pulled the throttle back. I pulled it back to idle and it stayed running so tried to go into my slip. Went the 100 or so yards of no wake to our marina then as I pulled up to our slip it stalled. Luckily I had gotten close enough a dock neighbor was able to grab us and get us in.
Pulled the filter/separator and emptied out the contents and it was fine. Put it back on and still no luck. Ended up pulling the carb off and bringing it home. Plan to order a kit tonight and rebuild it.
The only other things I can think of is vapor lock, the hose from the tank to the filter is getting sucked closed, or the electric fuel pump going. I really don't think it i any of those as it runs fine for awhile then acts up. In all of my years of racing I have only ever seen vapor lock a couple of times so doubt it is that. The fuel hose would probably be a constant issue and fuel pump not real sure if it might be good for awhile then act up?
Trying to identify anything that could possibly be causing this issue to figure it out. Definitely feels like fuel related. It is also possible the filter/separator is getting plugged but hard to believe the last one plugged up in 1/4 mile (maybe 10 minutes of running).
Engine ID is 0w383495
My carb doesn't have a choke. It's a TKS (turn key start). It has an electric solenoid that I think enrichens the carb at cold start.
https://www.mercruiserparts.com/bam/subassembly/31841/11741/80
Here is a link to the carb style I have >