I have a 2000 25 HP Mercury Outboard 2 stroke. I have put in a new carburetor kit, replaced the fuel tank, fuel hose, primer bulb, filter, fuel lines, primer diaphragm, motor fuel connection and fuel line fuel connection. I have gone from motor starting only, starting but dying when put in gear, running at WOT for 1 minute and dying with immediate restart to now starting, running at WOT or mid for 10 or 15 minute run, shutting down when I arrive at my spot. After 30 minutes of fishing, motor restarts on first pull, but dies when forward is engaged. I have to pull the cowling, slightly rev the motor a few times and then put in gear.

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Runs fine after that. Idle seems to be at the right RPM. I suspect some minor adjustment, but I can't find a reference on the procedure and don't have a manual.

Download Mercury outboard repair manual, mercury outboard repair manuals online, mercury 115 hp outboard 2 stroke manual, mercury 40 hp 4-stroke outboard service manual pdf instantly. This INSTANT REPAIR MANUAL DOWNLOAD for the Mercury-Mariner, Johnson-Evinrude, Suzuki, Honda, Yamaha 25HP outboard engines were designed primarily for factory service 25HP outboard technicians in a properly equipped shop.However, enough information in 25HP outboard repair manuals is given for do-it-yourself or apprentice mechanics to correctly and safely perform repair work to their 25HP. I have a 2000 25 HP Mercury Outboard 2 stroke. I have put in a new carburetor kit, replaced the fuel tank, fuel hose, primer bulb, filter, fuel lines, primer diaphragm, motor fuel connection and fuel line fuel connection.

Each repair noted above was in response to a specific problem ie. Fuel leak, no fuel, running problems etc.

Bought this motor from a 'Boat Mechanic' that said he went through everything. Also, not overheating and good water stream.

Does not appear electrical. You can try using a can of Power Tune carb cleaner that can be bought at the local Merc dealer before tearing the carb off. It will do wonders at times, and can save work. Make sure that the idle jet screw is turned out 1 1/2 turns from lightly seated, and that the air vent jet on the carb is clean. Adjust the idle jet, after the motor has warmed up, so that it is set in the middle of the lean and rich missing of the motor. Best is to go a little to the rich side a blade with of a screwdriver.

If the motor still dose not run good, use a piece of clear tubing in place of the gas line to the carb and check for air bubbles in the fuel supply indicating a air leak. Remove the clear tube and replace the standard fuel hose when done. JMO Oldman570. Thanks for the advice. I ran it yesterday after taking it apart and inspecting everything and the stalling while engaging forward was no longer an issue.

It did flood on me after the third stop, but getting it into gear was no longer a problem. I like the tip about the clear hose. That would help diagnosing air leaks. I did discover that the previous owner or 'mechanic' gutted the thermostat.

I have a new one on order. I figured that inconsistent head temperature may have an effect on setting carb. Orbanp had also made the same recommendation and provided a manual that has been very helpful.

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