Ran great for 3 cruises after carb rebuild but now sounds rough

jafiori

Recruit
Joined
Jun 19, 2010
Messages
4
I rebuilt the card on my 1981 25 HP johnson about 1 month ago. After a little tweeking the outboard ran great for about 6 hours (3 -4 trips). I took the boat out last weekend and the motor sounded very rough. No longer was there the nice consistant purr of the johnson but a much deeper rougher sound (but not quite skipping). Thinking that this was again a carb problem I took the carb apart today.

I drill small holes in the jet plugs to remove them. I drilled all three and began prying them out with a nail when I noticed one of the smaller plugs on the side of the carb fell out. Was this plug loose? Is a loose plug a possible reason why the motor ran poorly or do I have a problem outside of the carb. Please advise. If the plug is the problem how do you properly set them. They are cup shaped. Does the cup face out or in?
 

Daviet

Fleet Admiral
Joined
Sep 24, 2008
Messages
8,958
Re: Ran great for 3 cruises after carb rebuild but now sounds rough

The core plugs need to be tight to seal. If you put the core plug into the housing with the dome up, you can take a flat punch just a little smaller than the plug and flatten it out to seal off the passage. Make sure you don't go past flat, or it could leak.
 
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