sudden problem-2002 Merc won't start. choke?

[adobe wall]

I've had the boat for 2 months and have run it at least twice a week. Boat has a 2002 Mercury 2 stroke oil injected 90 hp with a jet pump on it and tiller handle.

Until two trips ago, it would fire the instant I turned the ignition key and pressed in (gave it some choke).

Two trips ago it would not start at the dock, I nearly ran the motor dead and finally resorted to ether. Motor would restart if warm very easily but would not start cold without ether. I pulled the plugs and replaced them with the same type of NGK's in the motor.

Went for another trip yesterday, same deal. Had to start it leaving and coming home with ether.

I've got a service app't with the dealer in a week and a half but it's fishing season and would really like to get going before that. Pulling anchor in front of shipping traffic with the kicker is not fun.

One thing I have noticed is that when I push the key in, I'm not getting anything that indicates the choke is coming on. Any suggestions? I'm mechanically inclined but the engine is new enough that I'm not going to completely disassemble it... wondering if I can easily check to see if the ignition switch is working right.

tia, aw

 

[Laddies]

Re: sudden problem-2002 Merc won't start. choke?

DON'T USE STARTING FLUID, it will damage the engine if you have to start it use some fuel in a squirt can, you can also try the manual lever on the primer body if that don't work ck the lines to the primer for kinks. the primer should click when activated if it don't ck at the primer wire connection for voltage

 

[JB]

Re: sudden problem-2002 Merc won't start. choke?

Howdy, AW.

Welcome to iboats.

No need to disassemble. Sounds like your choke solenoid (or primer, whichever) has failed. I don't know which you have, but you can see if they are working.

Take the bonnet off the engine and gain access to the carb throats. If you have choke at least one carb will have a butterfly near the intake. Watch what happens when you activate the choke switch with your key. If there is a choke and it doesn't move check the linkage to the electric solenoid, then the electrical connection to the solenoid.

If you have a primer rather than a choke you should see fuel injected into the carb throat when you operate the key switch. There should be a solenoid operating the injection.

Never use ether to start a 2 stroke engine. It has no lubricant and will wash away the oil coating the innards. It is also explosive. That can lead to a disastrous failure. Use a spray bottle with premixed fuel.

A Mercspert (like Laddies) should be along soon to correct or add to my suggestions.

Good luck.

 

[adobe wall]

Re: sudden problem-2002 Merc won't start. choke?

thanks for the advice. I was able to locate the priming solenoid, it's got a pushbutton on top. That alone was worth posting here, should keep me from using the can of ether.

As for the safety of ether vs. gas, one buddy of mine ended up holding a flaming can of gas from trying to spray it into the carb and was severely burned. While I'm aware that ether is a pretty dadgum good cleaner, I think that very short bursts are safer than holding the little spray bottle o' gas. There is a very real danger of ether detonation on engines equipped with intake air preheaters but I've never heard of those on an outboard...

Will take the boat to the river tomorrow to see what happens. Swapping the primer solenoid will be quite easy, have chased down the wiring connections and it looks like it's attached with only one bolt. Piece of cake.

thanks again, not meaning to be argumentative at all on the ether usage. Best situation would have been to stay at the dock instead of potentially putting myself in front of a ship with no means of starting the big motor.

regards, aw

 

[adobe wall]

Re: sudden problem-2002 Merc won't start. choke?

one last question, looking at the parts diagram it sure looks like the prime solenoid is called the "enricher valve"?

If that's it, I should be able to have my hands on one tomorrow.

regards, aw

 

[j_martin]

Re: sudden problem-2002 Merc won't start. choke?

Adobe,
Before you change out the enricher valve, probe it with a volt meter or test light to be sure it's getting power. The trouble could be in the key switch or in the harness.

Not to be contentious, but ether will wreck your engine in a heartbeat. You weren't told to hold a half empty gas can upside down and try to dribble a little into the carbs, waiting for a backflash to light you like a torch. (like your buddy did.) Put some 50:1 gas/oil mix in a spray bottle and squirt it in like you do with the ether.

hope it helps
John

 

[jmburock]

Re: sudden problem-2002 Merc won't start. choke?

You should hear the solenoid click when you push the key in to choke, do it without the starter engaged so you can here it. Either way, I would think it would start without it in most cases if it were truely getting any gas to the carbs..

 

[Waliczek]

Re: sudden problem-2002 Merc won't start. choke?

This is amazing, The same thing is happening to me. I have 2002 40 HP merc, oil enjected. It started at the beginning of the trip, and it will run fine for as long as I don't turn it off. I stop to do some fishing, and when I am ready to move to a different spot, I can crank until hell freezes over, and it will not start. A couple times, my trolling motor gets me to the ramp. Some times a tow. Mechanic at the shop thinks I am nuts. It always runs fine for him.
The last time I pulled the plugs while on the water,. wet,wet, wet.
I was very careful the last time to not use the choke button. I pulled the fuel line off the motor, and cranked until I purged the engine and it sputtered to life and at last it smoothed out, I re-attached the fuel line and away I went. I am getting very afraid to take the boat very far afield to do any serious fishing.

Any hints or fixes would be greatly appriciated.......

PS: This is a great forum, I am sorry my first post is a gripe.
Tom

 

[adobe wall]

Re: sudden problem-2002 Merc won't start. choke?

It's fixed.

I was right on the edge of ordering the enricher solenoid assembly, but did pull the harness connections and put a test light on the two wires from the ignition switch. No light. Then I checked the light and the bulb was burned out.

Got the meter out, and still had no juice from the ignition switch. Laying on my back I could see underneath the small control panel at the base of the tiller handle once I pulled off the bottom cover. There are five wires coming out of the back of the ignition switch. The black one was broken off clean at the back of the switch, and two other wires were halfway cut.

How it happened became obvious when I tried to remove the ignition switch. It's a fairly long assembly made longer by the fact that the harness connections at the back of the switch are epoxied in. There was enough epoxy back there that the switch assembly was within a hair of being as long as the depth of the box. Removing the switch broke the other two wires.

Looks like Merc had some long switch assemblies and made them work. The replacement was $56, but could have been had for $38 off the internet (didn't want to wait, the fish really are biting). The replacement was built the same way but had about 1/4" less epoxy on the back, so it fit easily.

Yes, I could hear the solenoid clicking when I pushed in the ignition switch with the new switch. No clicking noise with the old switch due to the broken wire. Engine fired with the first turn of the switch.

thanks for the help, I can cancel the dealership appointment for next week and go fishing. Sturgeon tomorrow for dinner.

regards, aw