Greetings all. First time post. I have a mercury 40hp 2 stroke (1994ish?). I have rebuilt the carbs and it runs pretty nicely but I have discovered a fuel leak. I traced it down to it was leaking around the outside of the carb float bowls. So I pulled them back off the motor and 'gooped' around the bowl and sealed it up as best I could. ....still leaked! Upon deeper inspection, I found that the seal was being 'pushed out' from the inside hanging outside the bowl!? I was VERY perplexed! The ONLY thing I can attribute that too is when I pump fuel delivery bulb until it is 'hard', I am forcing too much fuel into the system and it is causing the seal to blow out and leak.? There CANNOT be that much pressure being generated by the fuel pump. ...right? What am I missing? Is there a fuel 'check ball' that is supposed to keep fuel from draining out? Could that be a contributor? I can't come up with any other explanation as to why this could be happening.? Any help? (btw, it's happened on both carbs! (it ony has 2)). Has anyone ever experienced something like this?
