1987 Evinrude XP200 - major tune up (??)

[dehydrated]

Re: 1987 Evinrude XP200 - major tune up (??)

one full turn equals 1degree of timing clockwise advance counter clockwise retard arm with locknut under flywheel right side if looking at carbs

 

[OldPcGuy]

Re: 1987 Evinrude XP200 - major tune up (??)

Got it... THANKS..!!

 

[OldPcGuy]

Re: 1987 Evinrude XP200 - major tune up (??)

Just looked thru the schematics and while it notes this hose, and that hose, this "Tee" and that Tee... and check valves that LOOK like tees... whew..!!

Anyone got a list of hose sizes for fuel (to carbs), recirc, and whatever else I can/should check/replace..?? And... how MUCH (length) of each I'll need..??

 

[dehydrated]

Re: 1987 Evinrude XP200 - major tune up (??)

bleed hose are3/32 should need about 10ft carb fuel lines are3/16th i/d should need about 12ft main fuel line should be 3/8 id

 

[j_k_bisson]

Re: 1987 Evinrude XP200 - major tune up (??)

You should need about enough fuel line that it cost you first born. Watch out that stuff is like gold as you are soon to find out. But there is a difference from old omc/evinrude hose and the new stuff. The old stuff is not ethenol rated and the new stuff if. Might want to keep you eyes out on what you are buying.

 

[dehydrated]

Re: 1987 Evinrude XP200 - major tune up (??)

get your fuel lines at napa auto parts part # h173 $ 1.05 ft for the 3/16ths

 

[j_k_bisson]

Re: 1987 Evinrude XP200 - major tune up (??)

They just don not have the 1/8" for the recirc lines.

 

[OldPcGuy]

Re: 1987 Evinrude XP200 - major tune up (??)

Understood. EVERYTHING that can be... should be "ethenol rated". And as you mentioned... it is not inexpensive. That's why I'm trying not to buy more than I need, nor have much 'waste'...

I actually ended up not buying any hose today... I need to do some better measuring before making the plunge. The line from the 'new' tank to the filter/water-separator is 'old' type hose, and I'd like to change it to 'safe' hose before I start using it.

And... of course... there is a new fuel/filter water-separator to replace the old one... and plumbing as well... and on and on...

Got side-tracked today with Grandkids... not much work on the boat got done. I did get some rubber piling bumper up on the dock... with one Grandson putting washers on screws for me. He had to 'warn' me a bit after I dropped a couple screws into the canal... HA..!!!

Anybody got a recommendation for types/numbers/source for "tees" used in the fuel/recirc system..??

 

[j_k_bisson]

Re: 1987 Evinrude XP200 - major tune up (??)

I just reused the old ones .I had a butter container of Isoproplene on the table where I was make the lines. Take each line off the tee. Dunk the T in the iso then scrub with tooth brush, bloww off with compressed air. Just Reuse them.

Watch out for the check valve in the recirc line coming from the bottom of the motor to the top. That one is $30 bucks and come appart I think. Mine did and I snapped it back together and reused it. Don't know know if I should of though.......

Get what hoses you can at your hoses at the auto stores. It's only $1.25/ft The stuff youy can't like the 1/8" and 3/16" get from the dealer. Save where you can. The autostore stuff now a days is Ethenol rated too even if it doesn't say it Has to be, to be certified for auto use after such and such date. Trust me Auto Engineer.....

 

[OldPcGuy]

Re: 1987 Evinrude XP200 - major tune up (??)

Thanks..!!!

 

[OldPcGuy]

Re: 1987 Evinrude XP200 - major tune up (??)

Grrrr.... went through ALL carbs again... found mis-aligned floats in 4 of the carbs... not 'slightly' off... WAY off..!!! This isn't something "I" did going through them... How these floats got so screwed up.... I don't know.

Now everything is back together and the motor won't spin faster than 4,000 rpm... WTF..???!!!!! Did I burn a piston, trash a cylinder..??

Criminy... now I have to get a compression tester and check THAT aspect... then start from where...

Probably have numerous things 'going on' here and I'm fixing one, and finding another... (and hopefully not damaging anything) All 'speed runs' are VERY short duration, just to get up on plane and 'feel' if there's any power. Before going thru the carbs for the second time (checking the floats) it actually ran BETTER... (???)

Think I'll take the day off... it's too hot for the aggravation...

 

[j_k_bisson]

Re: 1987 Evinrude XP200 - major tune up (??)

Must be nice to be too hot! Its cold here, mid 30's and very windy. Almost too cold to work on the boat. Almost!

Before you next run go step by step through the fuel system all before you take it out again. Also check compression, and spark gap on every cylinder. The spark gap checker is cheap and can be picked up at any auto store. This device will tell you is you have good spark.

With motors it can only be compression, fuel or spark. Spark and compression are very easy to check for. The fuel is the dificult one.

 

[nymack66]

Re: 1987 Evinrude XP200 - major tune up (??)

FYI Ace hardware has correct size for the re-circulating hoses (fuel rated) plus they look semi clear or see through which is a plus, since you can see the suckers working and not clog? At 1.25 per foot its a deal ...

 

[OldPcGuy]

Re: 1987 Evinrude XP200 - major tune up (??)

Thanks.!! I'll stop by the ACE and take a look at that recirc hose. While I'm waiting for the heat to subside I finished off a couple of DVAs that hopefully will allow me to further check the electrical system.

These pics show the finished product(s)... the meter is one from Harbor Freight that was just on sale for about $5. I keep a couple around as 'loaners'..

I used the schematic found here on Iboats... found two of the items at Rat Shack, and the capacitor took a bit more work to find locally. "Real" electronics stores are few and far between.

 

[OldPcGuy]

Re: 1987 Evinrude XP200 - major tune up (??)

Ok... three items... pulse valve, in-line fuel filter, and fuel pump.

Second first... with engine running, should the fuel filter be 'full'..?? or half full..?? When pumping the primer bulb the fuel filter gets about half full. When engine is started, the filter is basically 'empty'. I can see gas in it, but very little. Nothing changes when throttle is run up... very little 'observable' fuel going through the filter. Considering how much fuel these beasts consume, it doesn't appear to be much gas going in. Can't say I ever 'noticed' how it appeared before...

Pulse Valve... where IS this thing..?? It doesn't appear to be on the pump itself... can't seem to 'see' it on the crank case..

If it turns out the fuel pump is not working correctly, I've already got info on a pump 'kit', but since I'm using premix, and don't intend to run the VRO, is there a 'replacement' strategy that uses a different fuel pump..??

The oil line at the fuel pump, from the reservoir, is disconnected and 'plugged'. It appears that a low oil/low fuel flow alarm switch is disconnected as well.

Any thoughts..??

 

[OldPcGuy]

Re: 1987 Evinrude XP200 - major tune up (??)

The "black/yellow stop wires"... CDI says if disconnected at powerpacks and engine runs well, check key switch/harness/shift switch...

What exactly to the 'stop wires' do..?? Yes, stop the engine..?? But, how..?? Would they be part of the 'kill switch' at the remote control box..?? The key mechanism..??

As for testing at the coils... CDI says test voltages of 'orange' wires from PwrPck "while connected... does one need to install an 'extension' from the coil to the lead to clip the tester clip to..?? I've clipped the neg lead from my meter to the orange wire, and the pos lead to where the orange wire connects to the coil... and it reads 300+ volts. The next coil tested only showed 16 volts..(!!?!?!) I just wanted to see if there was a difference...

Then CDI says then 'test the orange wire disconnected'... does this mean one lead on the orange wire, and one to ground..?? How about between the coil and the plug...??

Meanwhile, I'll simply test each coil for resistance... THAT I can handle... :-|

 

[daselbee]

Re: 1987 Evinrude XP200 - major tune up (??)

The "black/yellow stop wires"... CDI says if disconnected at powerpacks and engine runs well, check key switch/harness/shift switch...

What exactly to the 'stop wires' do..?? Yes, stop the engine..?? But, how..?? Would they be part of the 'kill switch' at the remote control box..?? The key mechanism..??

Yes exactly. The key switch grounds the black/yellow wire(s) to signal the pack to quit making spark.

As for testing at the coils... CDI says test voltages of 'orange' wires from PwrPck "while connected... does one need to install an 'extension' from the coil to the lead to clip the tester clip to..?? I've clipped the neg lead from my meter to the orange wire, and the pos lead to where the orange wire connects to the coil... and it reads 300+ volts. The next coil tested only showed 16 volts..(!!?!?!) I just wanted to see if there was a difference...

Not quite right on this one... Take a piece of wire maybe 2" long, strip the ends, put one end under the rubber orange wire cap, and press it on the coil post. This leaves a pigtail to hook your meter to.
do not put the meter inline (in series) with the orange wires to the coil.

Then CDI says then 'test the orange wire disconnected'... does this mean one lead on the orange wire, and one to ground..?? How about between the coil and the plug...??

Yes, disconnect the orange at the coil and measure to ground for this test as described by CDI. Never measure the output of the coil (large wire to plug) with a multimeter. The voltages are around 20-30 KVA and will fry the meter.

Meanwhile, I'll simply test each coil for resistance... THAT I can handle... :-|

From experience, that will not tell you much.

 

[OldPcGuy]

Re: 1987 Evinrude XP200 - major tune up (??)

I DID try the voltage from the coil to the plug... not long enough to fry the meter it seems. Thankfully, it's a 'cheap' meter..

I'm in 'brain lock' as of late... doing electrical work (residential) I've used 'pigtails' for decades to 'tap' into a connection..
"Need some 'hot'... pigtail into this line..."

I'm running into issues that may lead to the remote control...(??) The overheat horn comes on, or stays off, independent of whether the engine is 'hot' or not... Motor hasn't run all day, turn the key on and the horn starts and keeps going, engine running or not. Come back 5 mins later, the horn 'chirps' then stays off with engine running... stop the engine.. re-start immediatly, horn back on... ugh..!!!

Once, I turned the key on... got the 'chirp'... then got distracted by a Grandchild working a dock-line... so didn't start the engine. Three minutes later, the horn came on (engine not running)... and stayed on. Engine on/engine off... horn always on.