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98/Honda 9.9 stalls with cowling on only

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  • 98/Honda 9.9 stalls with cowling on only

    This is a 1998 9.9, BABL-1204405 that just started to cutout.I found that if I removed the cowling the engine would run. Reinstall and chokes out with in a minute. I have removed and soaked the carb in carb cleaner and reinstalled. Engine did run smoother but still chokes out and stalls when the cowling is replaced. i have read the other posts regarding this and am not pinching any lines ect. I do seem to have some exhaust in and around the engine but not much? Would a little be enough to choke it? Cant spot the source either. Anyone offer a solution or suggestion . Thanks

  • #2
    Re: 98/Honda 9.9 stalls with cowling on only

    had the same problem with an older BF8,the exhaust tube is likely cracked andyou are getting exhaust gases sucking in.the motor is fresh air starved.check the tube for leaks, and repair or replace !

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    • #3
      Re: 98/Honda 9.9 stalls with cowling on only

      Thanks scotty I will have to locate the leak and repair.

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      • #4
        Re: 98/Honda 9.9 stalls with cowling on only

        I was just scanning through a Seloc outboard manual.Looks like I will have to remove the lower unit then the extention case.Just to access the oil pan and exhaust gasket. Has anyone out there performed this before? I would hate to go to all this work if it was not the real problem. thanks

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        • #5
          Re: 98/Honda 9.9 stalls with cowling on only

          they are a bugger to get to...we removed the head to access it from the top.i think that was even more work.you would think the honda design team wouldtry to make them a little easier to work on.

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          • #6
            Re: 98/Honda 9.9 stalls with cowling on only

            Make sure the carburetor intake is facing down not up. This has been a problem in the past.

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            • #7
              Re: 98/Honda 9.9 stalls with cowling on only

              thanks but it is installed facing down.

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              • #8
                Re: 98/Honda 9.9 stalls with cowling on only

                Just out running this thing again and while cleaning the water outlet some water filled the bottom of the cowlig and it was bubbling likre mad. I presume this will be my exhaust leek i'm looking for???

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                • #9
                  Re: 98/Honda 9.9 stalls with cowling on only

                  Have removed power head to inspect the exhaust manifold and discovered a badly corroded exhaust chamber. This bolts down a exhaust chamber over a exhaust plate to the oil pan. It must vent the upper extension piece to atmosphere through the cowling??. Anyways these parts are toast! Have new ones on order and I need to repair the corrosion to the mating surface while i wait. May be to difficult to weld and machine so I am going to try a two part Aluminum product to fill lost material.

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                  • #10
                    Re: 98/Honda 9.9 stalls with cowling on only

                    I guess that is a common problem. I have a friend that had the same thing happen to his 15hp Honda which basically the same engine. I have an older(93?) 15 Honda and so far no problems and it has seen nothing but saltwater usage, probably has inexcess of 3000 hrs, but it gets a good fresh water flush after every use.

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                    • #11
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                      Re: 98/Honda 9.9 stalls with cowling on only

                      Just to update anyone following this problem. I have sand blasted and filled corroded areas with a epoxy aluminum filler, reinstalled new exhaust chamber and plate with gaskets. power head back on and everything back together. Purred like a kitten. Had a tough time with two broken fasteners though. anyways ready to go problem solved.

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