Outboard help

Matt B

Matt B

RAMONES
Forum Supporter
After a good run with my 2001 Honda 9.9 four stroke, I’m having some issues. I thought it was a fuel line or fuel tank issue, but now I’m not sure.
Yesterday after a good run out and stopping to have lunch I couldn’t get it to start. It would start to start if I had it choked but immediately die. At one point I got it running and up on plane but I powered down and it stalled and I ended up getting a tow.
Today in the driveway I removed the fuel sender part from the tank and didn’t see anything obviously amiss. The motor started, choked, first pull. Ran okay for a bit un choked, but then stalled all of the sudden. Primer bulb was firm. Then it would only start and run choked. Take the choke off and it stalled.

I never changed the spark plugs. Figured I’d start there. After that, I guess I need to go through the fuel system.

Now that I type this, I realize I need to look at any fuel filters in the system.
 
Ok I had a 2006 mercury 9.9. At one point it would start, rev up, but try and get it to idle and it would die every time. Sound familiar? It's your carburetor. You're gonna have to pull the carb. You have 2 jets inside the float bowl. One is the main jet. The other one is the idle jet.(the smaller jet of the 2). Your idle jet is clogged. Doesn't take much as the hole in the jet is very tiny. Take a foot long piece of stainless downrigger wire, and unravel it. Downrigger wire is made of several stands twisted together. Take 1 strand, it'll have a bunch of kinks in it from being twisted. Unscrew the jet from the carb. Squirt a shot of wd40 on the jet and run the downrigger wire back and forth through the jet several times. Rinse with wd40 or brakeleen. Put the jet back into the carb. Carb back onto motor. Betcha it'll run like a champ. Prolly wouldn't hurt to pull and clean out the main jet while you're in there.
Lemme know how it turns out.
 
Here's a pic of unwound downrigger wire. There are 7 stands. You only need one.
 

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Ugh. I got a frozen screw on the case. And the case is plastic so I can’t hit it with a torch or anything. I’m hosed until I can get that screw loose. Of course, 2 others seem to have walked out!
 
some good reading to help:

2001 Honda 9.9 HP Four Stroke ... stalling

Trying to help neighbor with his stalling issue. I am new to forum but, have had great success with input and feedback. Thanks everyone in advance. Boat/Engine is used in fresh water and well kept. It starts up easy and runs well for a while at low idle (while trolling/fishing). Then...
forums.iboats.com forums.iboats.com

2001 Honda 9.9 issues

Hello, purchased a nice 9.9 from a next door neighbor, he did a test in a barrel, started right up, runned smooth, shifted forward and reverse with no problems, ren just fine without issues (not visible to me). I shipped this motor overseas to my father in law and shortly after that we flew...
www.marineengine.com
 
Matt B said:
Ugh. I got a frozen screw on the case. And the case is plastic so I can’t hit it with a torch or anything. I’m hosed until I can get that screw loose. Of course, 2 others seem to have walked out!
Click to expand...

Sometimes cranking it down a bit tighter, then trying to loosen the screw works.
 
Peyton00 said:
Sometimes cranking it down a bit tighter, then trying to loosen the screw works.
Click to expand...
I hear ya, just gotta break loose whatever corrosion seems to be holding it in place. I swear I have gotten it to click tighter but still no luck. I soaked it in wd-40 and another lube, have been whacking it with a hammer and punch. Maybe an overnight soak with the lube will help.
 
Liquid wrench was what i grew up using on those fasteners that were stuck. My son introduced me to a product called bolt breaker that he uses on marine applications. It might take a while to loosen it up.
 
I gave it several more substantial whacks with the hammer and punch and tried it again before dinner and I got that sumbitch loose, the cover removed and the spark plug boots off. Saving the rest for later but glad to at least be making progress again. That was annoying. Man, I reeeaaally don’t wanna have to dig into the carb. But it appears that I’ll continue to be my own marine mechanic for the foreseeable future.
 
Carbs are amazingly easy on out boards. Very simple and easy to clean. Take pictures of each step along the way with your phone. I use a carb cleaner that has the spray tube to blow through the jets and this usually gets the job done. It also helps if you can let them sit in carb cleaner overnight. Spray some in a jar and drop the parts in, then close the lid before it evaporates. The most important thing is getting the mixture screws set right. Before taking them out, turn them all the way in and keep track of the number of turns. Write it down! You can also find all kinds of info on the web. I just did a 34 year old Suzuki. Came out great.
 
You'll get a hang of the carbs pretty quick. It can be a little intimidating the first time, I know it was for me on my old Yamaha 40hp 2 stroke and I have a mechanical background, but all with fuel injected stuff. In the end I had those things off and taken apart and reassembled and tweaked and cleaned so many times that I could probably do it with my eyes closed. I had a little jewelry ultrasonic cleaner from harbor freight that I tossed most of the parts in that made cleaning super easy too.
 
Shit, I just got pnw pwned by the Captain.

In other news I replaced the spark plugs and picked up some carb cleaner, with the little red tube included. I ordered a fuel filter. I’ll need to get the carb gaskets ordered up before digging into that side of the outboard.

I think I can order those stupid little machine screws with washers (it seems like the OEM ones have a flat washer integrated, it doesn’t thread off) that attach the upper motor casing. I might look around at the hardware stores for stainless stuff that will work but I don’t have a lot of hope. Other than making a trip up to Ballard Hardware which I have not done in a very long time.
 
I can't speak for a 4-stroke, but my Merc 20hp 2-smoker was doing sort of similar things...It usually would start no problem, idle no problem, but then when I went to cruise across the lake it would cut out and just die.
But I did get to a point where it didn't want to run unless choked. So I rebuilt the carb, which was probably needed anyway as it's a 2001. Well, still had the issue.
I know you mentioned the fuel line. Did you check it?

It turned out I was using an old Quicksilver 6.6g gas tank that also had an old fuel line. I took the line off and OMG...i had chunks of the inside of the line just falling out. It was disintegrating inside had was almost like hard pieces of jelly. The internet then told me this is a common thing with the gray fuel lines that Merc and so many others used. These chunks were just cutting off my fuel supply. That's why it would idle fine, but increase the pressure with more throttle and it would plug & die.
Dumped all that gas, treated the old tank with some cleaner, new gas and new fuel line and presto! She cruised like a brand new motor!
Has run great for 2 years now.

And also check that your vent on your tank is actually venting. I have to have mine nearly falling out or it causes an air lock and starves it of fuel. Sometimes it's the stupid stuff. Good luck!
 
I also saw that about fuel lines delaminating and clogging. I have not yet pulled or inspected fuel lines. But I will. I am trying to figure out what I need for the carb before pulling it, but guess what, it’s really hard to find a decent YouTube video on this, let alone the items for sale where I am confident it’s the correct part(s). It looks to me like I need 2 flat gaskets but the “kits” have an O-ring type gasket along with one flat gasket. Some have some kind of vibration damping plate. I’d like to have the parts before any disassembling. The Honda owners manual I downloaded does not do a good job supplying parts numbers. Anything at all complex they say take it to a dealer.
 
sonic cleaners are routinely used in OB shops to clean clogged carbs. And using Sea Foam in carb outboards is always a good idea..
 
SurfnFish said:
sonic cleaners are routinely used in OB shops to clean clogged carbs. And using Sea Foam in carb outboards is always a good idea..
Click to expand...

Okay but it’s not like I have an ultrasonic cleaner tank…
I used to work at a clock shop 30 years ago and had access to one then but it isn’t a normal household item, ya know?
 
Matt B said:
Okay but it’s not like I have an ultrasonic cleaner tank…
I used to work at a clock shop 30 years ago and had access to one then but it isn’t a normal household item, ya know?
Click to expand...
$30 at Walmart, Amazon same, for one big enough for an OB carb. Use mine frequently on anything metal that needs vibe scrubbing..
 
SurfnFish said:
$30 at Walmart, Amazon same, for one big enough for an OB carb. Use mine frequently on anything metal that needs vibe scrubbing..
Click to expand...
More appliances! More more more! :LOL:
 
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