'97 Evinrude 25hp throttle issue

[jbuote]

Well,
​I meant more like running it in your barrel at least to make sure it's still runs and idles properly..
​If the timing was off, are you going to have to re-adjust idle and/or mixtures or anything? (can get close in barrel, but final on lake)

​I guess what I mean, is since something changed, start over as if it's the first time running it and check it over from scratch..
​Maybe that's not necessary, but I've been doing that with mine..
​Find and fix something, then start it up and pretend I never have. Check it all again.. Find the next thing, fix it, barrel test...

​Finally, I won't find anything else and should be good to go for lake testing.. Find something, fix it, lake test etc. until there's nothing left and it will run just fine...
(If that makes sense...)

​Maybe the Pro's here have better thoughts.. (Probably do.. LOL)

 

[WhiteRice]

Ok... Before I started it back up today, I replaced the fuel lines from the tank all the way to the carbs. Reason for this is that I opened the carbs again an saw some trash in the bowls and also some trash in the fuel pump screens. Re-cleaned the carbs and throttle body. Put everything back together and primed it. Took a few pulls but then it fired right up. Smoke was about the same and I could not really notice a change in idle. After about 5 minutes of running I began to have some concerns. I have always had a few drops of black oil coming from the upper exhaust but today I was having "milky" drops coming from the upper exhaust. This really looked like mixed water with oil. Compression tests before starting any of this throttle issue looked fine but I am wondering if the corrected timing "awakened" a cylinder that had a bad O-ring. I don't believe this motor has an actual head gasket and I didn't have time to pull the head today to inspect. I did pull the plugs once shut it down and they were all normally wet.

 

[flyingscott]

Does that motor have the OIS ignition on it. It's been a while since I have seen a 3 cylinder 25 but I thought they had OIS ignitions.

 

[WhiteRice]

I would have no idea about that flyingscott. How would I check and what impact can this have with my issue(s)?

 

[flyingscott]

It usually says what it is on the cdi box. If it is a an OIS it can cause all kinds of problems. Put up a pic of the ignition system

 

[WhiteRice]

Don't have a pic of the ignition system handy (at work). This is the best I can do right now

http://www.iboats.com/Ignition-Syst...255354--session_id.833897994--view_id.1548381

 

[flyingscott]

I believe that is an OIS system try here for diagnosing it they may have the info you need http://www.cdielectronics.com/troubleshootingguide/. You have some troubleshooting to do

 

[WhiteRice]

That's quite the troubleshooting manual! Issue is that it does not show a 2 stroke 3 cylinder in my application (25hp). Only shows a "Quick Start" 40hp-70hp. Guess I need to check a part number on the unit itself and compare.

 

[racerone]

Yes it is an OIS machine !

 

[WhiteRice]

racerone... Out of curiosity, where did you find that info? Apart from the schematics on here, I cannot find much reference material on these 3 cylinder motors (especially the 25hp). Even iBoats customer service could not give me a definitive answer on if I was ordering the correct service manual when I was trying to find it...

 

[racerone]

I have more than one of those motors for rebuild and parts.---I have nearly 50 years experience repairing outboard motors !

 

[WhiteRice]

In your experience, are they worth this much trouble? Just almost seems like a Flow Chart from Hell with this one. lol

 

[racerone]

They are an excellent machine.---Same main bearings on the crank as a 70 hp.----But if you do not have the proper manual and some experience than you will be challenged by them !!

 

[WhiteRice]

Was doing some research on the OIS and I have a question. If my motor truly is OIS, wouldn't there be an assembly for the optical sensor that I would have to remove before I took off the flywheel? There was nothing on top of the flywheel except the rope rewind system in the housing. Once the flywheel was off, the stator was there but that's it...

I took some pics of the power pack and the coils but I'm not sure if that will help anyone identify if this is an OIS unit.

 

[flyingscott]

That would be true of a V4/V6 motor. I believe your optical sensor is part of the ignition module that is why it costs $600. Racer will be able to tell you exactly where the optical sensor is on your motor.

 

[racerone]

It was stated that this is an ---OIS ----ignition engine.----Therefor it is.---The optical sensor is under the flywheel and so is the wheel / encoder that breaks the light beam !!!!----Not sure why I try to help folks with nothing but doubt on some facts.

 

[WhiteRice]

flyingscott... Thank you.

racerone... There was no doubting your knowledge but when I removed the flywheel and did not see anything resembling an optical sensor; I felt the need to ask. I may be new to these forums but not new to asking questions and validating information when I am trying to trouble-shoot something myself. Sometimes "I said it therefor it is..." is not helping to identify the issue. Sorry if you felt your toes were stepped on

 

[racerone]

The encoder wheel screws on inside / under the flywheel and is about $12.00------The optical senser is mounted under the flywheel and only about $ 320.00

 

[WhiteRice]

Thanks racerone. That clarifies a lot. When I looked at everything, it looked like it was all part of the stator assembly.

 

[WhiteRice]

UPDATE...

Took boat out yesterday and still cannot get WOT. It actually stalled out twice when I had it at its max throttle (about 7mph) but started right back up on the first pull. Idles flawlessly. Taking this to the shop on Thursday suspecting electrical issues possibly with the OIS or powerpack as racerone had pointed out. I have done the following:

Carbs THOROUGHLY cleaned. Fuel lines replace all the way to the tank. New spark plugs gapped corrrectly. Plug wires have solid continuity. Inspected flywheel keyFuel pumps operating correctly (screens are clear too). Fuel filter is clear. Checked cylinder O-rings and all are in great shape. Cylinder #1 at TDC registers at "T" on the flywheel. Carbs open fully when manually actuating the throttle linkage when running this in my flush barrel.

I'm at a loss and don't really have the means (know how) to test all the components of the OIS and powerpack. I appreciate all the help. At least I've gotten to know my motor a little better over the last few weeks thanks to you guys. lol