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Old 15-03-2015, 00:32   #16
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Re: At My Wit's End with My 2001 Mercury 5hp Two-Stoke Outboard !

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Originally Posted by Janae View Post
It's in great condition - other than the fact that I can't get the damned thing to run right.

We have continuous problems with flooding. We've recently replaced the filter, and the float needle.

We use high quality gas (ethanol free), 50:1 synthetic marine 2 cycle oil mixture as well.

We've taken the carburetor apart half a dozen times now. Thoroughly cleaned it out each time. Replaced the gas inside. Made sure there were no holes in anything, no leaks, no blockages, etc. It looks like it should be running like a dream.

However, it's always flooding. The float valve and needle appear to be working fine, in the right position, not sticking.

It's a 50/50 that can get it to start. If we don't flood it on start, we have to manually regulate the external fuel valve on the outside of the cowling to prevent it from flooding while it's running. This means, every 30 seconds or so, opening the valve for a second to allow some fuel to come in.

I'm not sure where to go from here. Rebuild kit? In my mind, flooding would suggest issues with needle/float valve - but we just replaced those. They APPEAR to be in the right position, not sticking, etc.

Does anyone have any words of wisdom?

I've got the same engine never fails to start. Cold, I close the choke and pull one time, then open the choke and half throttle.
Starts every time, more than 1 closed choke pull and it will flood.
Fully open the choke and throttle, if it does flood.


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Old 20-10-2015, 16:17   #17
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Re: At My Wit's End with My 2001 Mercury 5hp Two-Stoke Outboard !

I have fixed two of these with the same problem. Fuel is leaking around the needle valve.
replace o ring 25-16259
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Old 21-10-2015, 05:16   #18
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Re: At My Wit's End with My 2001 Mercury 5hp Two-Stoke Outboard !

Greetings and welcome aboard the CF, Doodad.
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Old 11-07-2017, 08:56   #19
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Re: At My Wit's End with My 2001 Mercury 5hp Two-Stoke Outboard !

I know this is an old post, but I found the solution to this problem and since it was never mentioned in this thread, I’d like to add it.

I have this 5hp Mercury motor, which is normally quite a good unit. After storing it dry of fuel last year, for the first time in many seasons, it demonstrated flooding when I first started it that spring. I removed the carburetor and examined the needle, seat and float; all was well. I reassembled and the engine ran fine for the season. This year I experienced the exact same problem. I took the carburetor apart again, and again the needle, seat and float were fine. But this time upon reassembly the motor continued to flood – what gives?

After disassembling again, I examined the fuel feed and the bowel more carefully. The fuel pumps into the carburetor body through an opening in both the bowel and body and into the needle seat. What had happened was that the bowel gasket had dried out right at the point where the fuel passage goes through. I believe what is happening is that the leaking gasket allows the fuel to go into the bowel directly, bypassing the needle valve, thus flooding the engine.

Using a small knife, I scraped some corrosion off the carb body and the gasket. The gasket is rubber and scratching it just a bit swelled the rubber a little. Upon reassembly, the flooding was fixed. The motor is running fine now and I have a new float bowel gasket on order, which I will install when it arrives.

The problem is not the needle, float or seat. It is the gasket. Take a close look at it.
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Old 11-07-2017, 20:08   #20
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Re: At My Wit's End with My 2001 Mercury 5hp Two-Stoke Outboard !

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Originally Posted by Homer Shannon View Post
I know this is an old post, but I found the solution to this problem and since it was never mentioned in this thread, Id like to add it.

I have this 5hp Mercury motor, which is normally quite a good unit. After storing it dry of fuel last year, for the first time in many seasons, it demonstrated flooding when I first started it that spring. I removed the carburetor and examined the needle, seat and float; all was well. I reassembled and the engine ran fine for the season. This year I experienced the exact same problem. I took the carburetor apart again, and again the needle, seat and float were fine. But this time upon reassembly the motor continued to flood what gives?

After disassembling again, I examined the fuel feed and the bowel more carefully. The fuel pumps into the carburetor body through an opening in both the bowel and body and into the needle seat. What had happened was that the bowel gasket had dried out right at the point where the fuel passage goes through. I believe what is happening is that the leaking gasket allows the fuel to go into the bowel directly, bypassing the needle valve, thus flooding the engine.

Using a small knife, I scraped some corrosion off the carb body and the gasket. The gasket is rubber and scratching it just a bit swelled the rubber a little. Upon reassembly, the flooding was fixed. The motor is running fine now and I have a new float bowel gasket on order, which I will install when it arrives.

The problem is not the needle, float or seat. It is the gasket. Take a close look at it.
Had this exact same problem with an old Tohatsu just a couple months ago. The bowl o-ring got flattened with age and let pressurized fuel from the pump seep past the passageway into the bowl thus flooding the flat chamber. Very frustrating to diagnose, but an easy fix once figured out.
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Old 11-07-2017, 20:35   #21
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Re: At My Wit's End with My 2001 Mercury 5hp Two-Stoke Outboard !

Oh, oh, oh...I am trying so hard to stop typing...
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