9.9 Evinrude, won't go over 3000 RPM

[DeanHensler]

Re: 9.9 Evinrude, won't go over 3000 RPM

I removed the carb again and checked the high speed jet. There are no numbers on the jet. The hole through the jet is very small. I cannot fit my 1/32 drill bit through the jet. What now?

 

[Tim Frank]

Re: 9.9 Evinrude, won't go over 3000 RPM

I removed the carb again and checked the high speed jet. There are no numbers on the jet. The hole through the jet is very small. I cannot fit my 1/32 drill bit through the jet. What now?

I think you need to make sure that you have the right jet installed before you reassemble the carb.
(on a positive note, you are probably now our resident expert at R&Ring that carb.... )

Could it be that the jet is actually undersize....and you are starved for fuel...as a previous poster suggested?
The 1/32" drill SHOULD go through the jet. If it does not, there may be a coating/build up of stuff inside.
Soak the jet in carb cleaner for a few hours and then try the drill again.

If you can't get the jet opened up to 0.034", it may be the wrong one.
You could try drilling it out with the 1/32 drill and see if it removes "junk" or actual metal.
If metal, it was definitely the wrong one....but you could then throw it back together and see if there is a noticeable improvement.
If so, at that point I'd get a new, correct jet.

 

[pn]

Re: 9.9 Evinrude, won't go over 3000 RPM

clogged main jet is a good one, but i've read the post and no one has even mentioned checking the fuel pump. It's always the carb, carb carb, but i'm tellin ya a stupid little hole in the fuel pump diaphram will give these same exact problems. drill it out, if that's not the fix then take a look at your pump.

 

[DeanHensler]

Re: 9.9 Evinrude, won't go over 3000 RPM

clogged main jet is a good one, but i've read the post and no one has even mentioned checking the fuel pump. It's always the carb, carb carb, but i'm tellin ya a stupid little hole in the fuel pump diaphram will give these same exact problems. drill it out, if that's not the fix then take a look at your pump.

I've already taken the fuel pump apart and checked for cracks. I held the diaphram up to a light and didn't see any small holes in it. Are there any tricks to remove the fuel pump from the equation? Any way to run gas straight to the carb and bypass the fuel pump?

 

[nwcove]

Re: 9.9 Evinrude, won't go over 3000 RPM

I've already taken the fuel pump apart and checked for cracks. I held the diaphram up to a light and didn't see any small holes in it. Are there any tricks to remove the fuel pump from the equation? Any way to run gas straight to the carb and bypass the fuel pump?

yep, just remove the female connector from the engine end of your tank fuel line, and do whats needed to connect it to the inlet on the carb. keep the bottom of the tank higher than the bottom of the carb and the tank will gravity feed to the carb. ( pump the primer bulb as normal)

 

[Tim Frank]

Re: 9.9 Evinrude, won't go over 3000 RPM

I've already taken the fuel pump apart and checked for cracks. I held the diaphram up to a light and didn't see any small holes in it. Are there any tricks to remove the fuel pump from the equation? Any way to run gas straight to the carb and bypass the fuel pump?

Oh boy.
Maybe we need to start over....in post #1 you said you'd ruled out the fuel pump.Now you are asking how to do that.

Exactly how did you test it?

 

[DeanHensler]

Re: 9.9 Evinrude, won't go over 3000 RPM

I think you need to make sure that you have the right jet installed before you reassemble the carb.
(on a positive note, you are probably now our resident expert at R&Ring that carb.... )

Could it be that the jet is actually undersize....and you are starved for fuel...as a previous poster suggested?
The 1/32" drill SHOULD go through the jet. If it does not, there may be a coating/build up of stuff inside.
Soak the jet in carb cleaner for a few hours and then try the drill again.

If you can't get the jet opened up to 0.034", it may be the wrong one.
You could try drilling it out with the 1/32 drill and see if it removes "junk" or actual metal.
If metal, it was definitely the wrong one....but you could then throw it back together and see if there is a noticeable improvement.
If so, at that point I'd get a new, correct jet.

Alright I just got done soaking the jet for 3 hours and right before I drilled it out I realized I made a mistake. I was trying to fit a 1/16 bit through there, not a 1/32. I don't have a 1/32, but by the looks of it that WOULD fit through the jet. A 1/16 will not, which means a its the correct jet for a 9.9, not a 15hp.

I'm going to try and bypass the fuel pump to see if I get any different results there, although I don't think I will because I have unhooked the fuel line from the motor before (while it was running) and it continues to do the same thing until it right before it runs out of gas, where it takes off like a bat out of hell. The fuel pump isn't getting any fuel when i do that.

 

[DeanHensler]

Re: 9.9 Evinrude, won't go over 3000 RPM

Oh boy.
Maybe we need to start over....in post #1 you said you'd ruled out the fuel pump.Now you are asking how to do that.

Exactly how did you test it?

I removed the fuel pump a couple weeks ago as someone suggested, trying to fix this same issue. I removed it and took it completely apart, then held the diaphram up to a light to look for any pin holes in it. I didn't find any. I put it back together and reinstalled it on the motor. I have the same issue before and after checking the fuel pump for a pin hole.

 

[DeanHensler]

Re: 9.9 Evinrude, won't go over 3000 RPM

I bypassed the fuel pump by hooking the gas tank directly up to the carb (putting the gas tank above the motor and giving the bulb a few pumps to get it started). I'm still having the exact same issue. Motor won't go over 3000 RPM in forward or 1500 RPM in reverse. The plugs are soaking wet. When I disconnect the fuel and let it run out, it takes off and runs to 5500 RPM right as its running out of fuel, then dies. I can hook the fuel back up, give the bulb a few pumps and it'll start right back up and idle all day, but the same problem keeps happening.

Today I let it run for a long time and felt the water coming out of the motor. It was cool. Is the water coming out of the water supposed to be hot? Lake is 60 degrees right now.

 

[Tim Frank]

Re: 9.9 Evinrude, won't go over 3000 RPM

Alright I just got done soaking the jet for 3 hours and right before I drilled it out I realized I made a mistake. I was trying to fit a 1/16 bit through there, not a 1/32. I don't have a 1/32, but by the looks of it that WOULD fit through the jet. A 1/16 will not, which means a its the correct jet for a 9.9, not a 15hp.

I'm going to try and bypass the fuel pump to see if I get any different results there, although I don't think I will because I have unhooked the fuel line from the motor before (while it was running) and it continues to do the same thing until it right before it runs out of gas, where it takes off like a bat out of hell. The fuel pump isn't getting any fuel when i do that.

No, you haven't confirmed anything.
A 1/16" drill is too big to fit the #54 also, and is not going to tell you anything definitive....no matter how it "looks"....
I completely understand your frustration, but you need to be really systematic.

You still need to verify that jet size..... or just buy the right one.
HD or a decent hardware store will have a 1/32 drill, or if there is a machine shop in the area, they'd have the right drills.

If you can find a piece of copper wire 16AWG, you can try that as a go-gauge for the #54 jet.

 

[DeanHensler]

Re: 9.9 Evinrude, won't go over 3000 RPM

If I'm going to take the carb back off the motor again, I might as well put a carb kit in it. Can someone tell me what the part number is for the carb kit on a 1992 Evinrude 9.9? Again the model number is TE10RELENA.

 

[AlTn]

Re: 9.9 Evinrude, won't go over 3000 RPM

BRP # 0439073...marineengine.com has schematics for you carb if you would like to see variations in the early and late production numbers for the carb cover and idle mixture needle...leeroysramblings.com might help you as well...post back and other options can be discussed

 

[Jim311]

Re: 9.9 Evinrude, won't go over 3000 RPM

If you're ordering a carb kit get a fuel pump rebuild kit too. Cheap insurance, easy to rebuild.

 

[Tim Frank]

Re: 9.9 Evinrude, won't go over 3000 RPM

If I'm going to take the carb back off the motor again, I might as well put a carb kit in it. Can someone tell me what the part number is for the carb kit on a 1992 Evinrude 9.9? Again the model number is TE10RELENA.

http://shop2.evinrude.com/Index.aspx?s1=mg8h6chopc9ak05lckaieofgk1&catalog_id=5&siteid=1

Part # 0431897

 

[the machinist]

Re: 9.9 Evinrude, won't go over 3000 RPM

Another thing, those fuel pumps can be a bear to reassemble properly, little springs & plungers inside that can get tipped as you reassemble things.

That tell tale water indicator is coming off the motor BEFORE it goes thru the block itself, like from the pump into the outer water jacket & then out the TT (it is just a water flowing from the pump indicator) so it will be cooler than exhaust water that has been heated by/then thru the motor.

 

[AlTn]

Re: 9.9 Evinrude, won't go over 3000 RPM

just read this in a seloc manual...float bowl off, carb upright, measuring from the bottom lip of the carb to the lowest corner of the float it should be between 1"-1 3/8" for the proper float drop..it also mentions a gauge < #324891 > used in setting the float height with the carb inverted, but I don't have any knowledge or experience with the factory float gauges. With your running problems I'd definitely lean towards the 1 3/8" drop.

 

[DeanHensler]

Re: 9.9 Evinrude, won't go over 3000 RPM

The orifice plug should be a #34. If it is indeed a 15 HP jet, it will be a #54.
The ID # = the number in thousand of an inch. i.e. a #34 ID = 0.034"
If you can't find the number on the part....if you have a numbered drill set, you can use a #67 drill as a "go" gauge and a a #63 as a "no-go".
If you don't have numbered drills, a 1/32 " drill should fit....a 3/64 should not ....if it is the right part.

If you somehow have the larger orifice, you can verify using a #56 as a "go" and a #54 as a "no-go".

Either way, the correct jet should be readily available, according to my chart it is OMC part# 324025.

I picked up a numbered drill bit set this morning to test the size of my high speed jet. I hope I have found my problem, can someone please verify this.

I was able to pas a #56 drill bit through the jet. This bit is labeled 56, .046 on the drill bit box.
I tried a #55, .052 drill bit and that would NOT pass through the jet.
Anything above a #56 will pass through. I am saying anything smaller than .046 will pass through, anything larger than 0.052 will not pass through.

Please confirm that my current jet size is too big for the 9.9. I really hope that I have finally found the problem.

 

[Tim Frank]

Re: 9.9 Evinrude, won't go over 3000 RPM

I picked up a numbered drill bit set this morning to test the size of my high speed jet. I hope I have found my problem, can someone please verify this.

I was able to pas a #56 drill bit through the jet. This bit is labeled 56, .046 on the drill bit box.
I tried a #55, .052 drill bit and that would NOT pass through the jet.
Anything above a #56 will pass through. I am saying anything smaller than .046 will pass through, anything larger than 0.052 will not pass through.

Please confirm that my current jet size is too big for the 9.9. I really hope that I have finally found the problem.

The good news is that you will have a huge amount of extra capability to do stuff now that you have that drill set.
The bad news is that the jet you have is DEFINITELY the wrong one. It is definitely a #54 jet... intended for a 15HP...someone either tried to "upgrade" the 9.9 to a 15....or swapped an entire carb that looked OK.
Either way....or even some other explanation, that combination will not work....as you are too well aware.

The best news is that I think you have found the root cause of your problem.

I apologise if you couldn't follow my test instructions; I know what I was trying to explain, but it can be tough to write it clearly.

Bottom line is that you need a #34 jet...OMC # 324025.

I believe that you are almost there!!!


Edit: BTW ~ The jet that you have is more than 2x the cross-sectional area of the correct one.....no surprise that you are having troubles.

 

[DeanHensler]

Re: 9.9 Evinrude, won't go over 3000 RPM

First off thank you all for the help! I picked up a #34 jet today and when comparing that to the jet that was in the carb, BIG DIFFERENCE.

Secondly, I HATE THIS MOTOR!!!! I got home today and swiched out the jets, then installed the carb just has I have 4 times now. I go to start the motor and it will not start. It will crank and crank and crank but not even attempt to start.

I checked compression and it's good at 100lbs each cylinder. I then checked for spark and it's not getting any spark at all, in either cylinder. I'm so sick of this motor. I thought for sure I had it fixed with that jet change and now its on to something else...

Where do I start with diagnosis of a NO SPARK problem? Again, both cylinders have NO SPARK.

 

[Tim Frank]

Re: 9.9 Evinrude, won't go over 3000 RPM

Start with the simple stuff.

#1 - make sure the kill switch clip has not been snagged and dislodged. (it's happened to me a few times)