Merc 25XD Carb Rebuild

jakeraap

Recruit
Joined
Oct 25, 2018
Messages
2
Hello all,

First time poster here looking for some advise.

Long story short, I picked up an old Alumacraft (84) to use as a hunting boat during the winter months dirt cheap. The guy I bought it from was definitely not the most knowledgeable individual in the world and couldn't tell me much other than he had it out the previous year and it would run but would die after about 15 seconds. I'm a pretty good diesel mechanic and figured the carb probably needed rebuilt.

Not being very experienced with boats or outboards I figured I'd give it the 'old college try' and ordered a full rebuild kit. I disassembled everything and found the float was about half full with fluid. I ordered a new float and reassembled everything. I should note I'm pretty sure I got the float and everything in the float bowl installed the correct way but not 100% sure as I forgot to take pictures of the bowl after disassembly.

After re-installing on the boat I fired it all up and it ran for a good 20 minutes or so while I adjusted the screw above the barrel. I couldn't seem to get it to idle right but I also had fuel coming out of the carb barrel and dripping down the front of the motor. Eventually the motor died (flooded I assume) and wouldn't start back up before I had to leave for work. The primer was soft and it took a lot of pumps on the bulb before it would get hard and it had fuel coming out of the bowl again with a squirt or two from the breather hole on top of the carb. I think my issue is with the float needle not seating all of the way but I'm not sure how to go about fixing this issue. After the rebuild I did have some gaskets left over and a small orange o-ring with grooves on one side I thought was a new float seal. I disassembled my carb again thinking I forgot to replace that but there is what seems to be a brass fitting surrounding the float needle. I didn't want to break anything so here I am asking for your expertise.

As I said I'm not very familiar with outboards at all but I'm pretty capable if someone can pass along some knowledge and give me ideas of where to go from here. Compression and spark is good as is fuel so I know my issue is something within the carburetor.

Thank you in advance and I apologize if this has been poster before. I searched around and wasn't able to find anything pertaining to the 25XD. Motor is an 85 serial number A108521 if that makes a difference for anyone.

If needed I can attach pictures from my phone later but am on my laptop right now and do not have them handy.
 

flyingscott

Fleet Admiral
Joined
Apr 8, 2014
Messages
8,293
Your float level is to high. Did you replace the primer assembly? Did you make sure the check ball and spring were in good shape?
 

jakeraap

Recruit
Joined
Oct 25, 2018
Messages
2
Is there a way to adjust the float height? The primer assembly got a rebuild kit as well, new check ball and spring included with the kit.
 

flyingscott

Fleet Admiral
Joined
Apr 8, 2014
Messages
8,293
Get a manual or find the float height you need. To adjust the float bend the brass tabs.
 

leonreno

Seaman Apprentice
Joined
Mar 17, 2011
Messages
36
On my carb I can turn the carb upside down and the bowl top is even with the bowl lip. I then can blow air into the fuel inlet and check for leaks, I just blow in with my mouth. This test the needle and seat for a good seal. Not all float levels are the same though, so you need to find that information for your carb. Good luck.
 
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