Hi there i am hoping for some help troubleshooting my Merc outboard. On the lake last year my motor would cut out on me. I was able to limp it back to shore by feathering the choke back and forth. What would cause this, bad gas, bad ignition parts, wiring? Also I have looked in the Sticky Files for parts for this year and I am having trouble finding what I need. I would like to replace the electrical wiring as they look to be corroded and cracked. Any part numbers for this and diagrams? Before this happened the motor was a running dream and I was very impressed.
Brad, the way you described the feathering of the choke seems to be a carb/fuel issue to me. If the wiring is cracked that opens up a whole new can of worms lol...
Replacing the stator on these is not cheap, but it depends on how bad the wiring really is. If it were me, I would strip down the carb carfefully, counting the number of turns on needle ( ie winding it in slowly until gently seated and noting how any turns until seated i.e 1 and 1/4 turns) check float height (1/4") and blast all jets etc out with carb or brake cleaner.
Renew fuel pump diaphram ( prob not even 15$)
- Check you got a nice spark on both cylinders.
- Good compression on both cylinders ( 120+psi on each +/- 5 psi)
If you done all of that correctly, I would say from and economical point of view, you have done all you can, without spending mega bucks on relacing expensive components like stators and coils etc.