2 stroke fuel system explanation?

rg2

Petty Officer 3rd Class
Joined
May 7, 2009
Messages
84
Can anyone explain to me, step-by-step how the fuel system on a small 2-stroke (25 hp) outboard works. I'm stilling having a problem with a rebuilt motor whereas it runs, in nuetral, for a short period of time and then quits as though you shut off the fuel to it. I thought if I understood the fuel system better then I could possibly isolate the problem. Examples of questions I have are: Why is there a fuel pump on the carb when I thought the fuel was pulled, by suction, through the carb and through the reed valves. What function do the reed valves serve? If you can direct me somewhere were I can read more about this I would greatly appreciate it. Thanks
 

moorecomp

Cadet
Joined
May 19, 2009
Messages
16
Re: 2 stroke fuel system explanation?

The fuel pump is to provide a positive flow of fuel from the fuel tank to the carb. The fuel/air mix enters the bottom of the cylinder, through the reed valves, on the upward travel of the piston. They are basically one-way valves that prevent the fuel/air mix going back out the intake when the piston is on the downstroke. The mix is pushed/sucked into the top of the cylinder, after the exhaust port has been uncovered and the exhaust leaves the cylinder and assists by drawing the fuel/air mix into the cylinder on the top of the piston.
 

Faztbullet

Supreme Mariner
Joined
Mar 2, 2008
Messages
15,930
Re: 2 stroke fuel system explanation?

Be careful as the wrong carb mounting gasket without the pulse hole will not allow fuel pump to operate, it will do as you describe..
 

rg2

Petty Officer 3rd Class
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May 7, 2009
Messages
84
Re: 2 stroke fuel system explanation?

Faztbullet, I will check the gasket because I did replace the gasket (the one between the carb and the intake manifold) prior to the rebuild. I purchased it through the Merc dealer but it's possible that I put it on wrong (assuming it can go back in more than one way). What exactly does the pulse hole do? Would the float level or inlet needle valve cause this sort of problem or would that be more detrimental to WOT performance. This stalling is occurring at idle with the motor in "N" and water muffs on. This same thing was occuring prior to the rebuild and I was hoping the rebuild would cure it but apprently there was more to it than that. Thanks for the help
 

section8

Petty Officer 2nd Class
Joined
Jul 27, 2007
Messages
120
Re: 2 stroke fuel system explanation?

might be so obvious that i need not mention. maybe fuel tank vent closed or clogged?!
 

Wingedwheel

Lieutenant Junior Grade
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Jun 16, 2009
Messages
1,071
Re: 2 stroke fuel system explanation?

Does it start right back up and repeat the problem? You may have an incorrect setting on your float level.
 

will941s

Chief Petty Officer
Joined
Oct 1, 2007
Messages
540
Re: 2 stroke fuel system explanation?

On the 25 merc, 2-stroke the pulse hole in the gasket creates suction to pulsate the fuel pump that is built into the side of the carb. If the gasket is mounted wrong the only way its going to stay running is keep spraying gas into the carb.

When you pull the primer it pushes on a plunger on the opposite side of the carb of the fuel pump. Sprays a little gas in the intake manifold and aids in starting. Once it starts the vaccum caused by the piston stroke runs through the front of the carb through the pulse hole and pulls on the fuel pump diaphram causing it to pulsate and creates a fuel flow into the carb, and into the engine while it runs. While it's at idle, the fuel flow is directed past the idle speed screw on the front, top of the carb...therefore that screw has to be set right to keep it running (about 1 1/4 turn from lightly seated), adjust it in water, in forward gear...idle. When you hit the gas, at about 1,200 RPM's the fuel flow is then pulled from the bottom of the carb through the highspeed jet that is placed in that brass screw in the bottom of your float bowl, bypassing the idle speed screw and taking it out of the equasion while at WOT. When you let off the gas and return to idle the fuel flow is then directed back through the idle speed jet and thats why when you let off the gas, the motor RPM's are a little erratic for about a minute into idle.

To the best of my knowledge this is how this carb works. If I'm wrong someone please correct me.
 

rg2

Petty Officer 3rd Class
Joined
May 7, 2009
Messages
84
Re: 2 stroke fuel system explanation?

Thank you everyone for all your help - I REALLY APPRECIATE IT. Tonight I rechecked the setting on the idle speed and low speed mixture screw. I noticed that while setting the idle speed the manual says to turn in until the screw "just touches" the cam follower then an additional 1/2 turn to slightly open the throttle plate. My problem is that I don't see any movement in the throttle plate unless it is awful minute? I noticed that when the motor begins to sputter if I squeeze the primer bulb on the fuel line it will pick up and run fine for awhile then repeat. I hooked up a different tank to it and the same thing happened. If the carb gasket is incorrect would priming the bulb make a difference? Do the fuel pumps on these things malfunction very often? Does this sound like a fuel pump problem (assuming the gasket is the correct replacement). As I said before, I reset the float height, replaced the worn inlet needle valve and cleaned the fuel filter prior to the rebuild.
 

j_martin

Admiral
Joined
Sep 22, 2006
Messages
7,474
Re: 2 stroke fuel system explanation?

Thank you everyone for all your help - I REALLY APPRECIATE IT. Tonight I rechecked the setting on the idle speed and low speed mixture screw. I noticed that while setting the idle speed the manual says to turn in until the screw "just touches" the cam follower then an additional 1/2 turn to slightly open the throttle plate. My problem is that I don't see any movement in the throttle plate unless it is awful minute? I noticed that when the motor begins to sputter if I squeeze the primer bulb on the fuel line it will pick up and run fine for awhile then repeat. I hooked up a different tank to it and the same thing happened. If the carb gasket is incorrect would priming the bulb make a difference? Do the fuel pumps on these things malfunction very often? Does this sound like a fuel pump problem (assuming the gasket is the correct replacement). As I said before, I reset the float height, replaced the worn inlet needle valve and cleaned the fuel filter prior to the rebuild.

That is EXACTLY how it will behave if the pulse hole is blocked.
 

will941s

Chief Petty Officer
Joined
Oct 1, 2007
Messages
540
Re: 2 stroke fuel system explanation?

LOL...Now ask ME how I know about the gasket thing. $150 dollars, thats how much it costed the mechanic to flip it around. And probably not a bad idea to replace the fuel pump also.
 

rg2

Petty Officer 3rd Class
Joined
May 7, 2009
Messages
84
Re: 2 stroke fuel system explanation?

I just wanted to thank you guys, specifically Faztbullet and Will for your suggestions. I took off the carb today and sure enough the gasket the dealer gave me is NOT exactly like the old gasket. It looks fine when you lay it on the carb but if placed on the manifold the vacuum port is blocked. The old gasket had a slotted opening whereas the new gasket just had one circular hole. Incredible! I haven't had time to pick up a new gasket yet and reinstall it but I'm 90% sure that should solve the fuel supply problem. Thanks again I really appreciate the help.
 
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