1981 Evinrude 9.9hp 2str starts but won't run - Page 3 - SailNet Community
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post #21 of 27 Old 08-16-2012
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Re: 1981 Evinrude 9.9hp 2str starts but won't run

Curiosity got the best of me. From a Google search:

"Timing : The throttle cam plate that rotates under the flywheel when you twist the twist grip & the plate has an raised line type mark on the front of it. This mark needs to be timed so that when you advance the throttle twist grip, that the carburetor roller is at this mark when the carburetor throttle shaft just STARTS to turn open . To adjust this on the older motors, you loosen the 2 bolts on the RH side of the plate & adjust the cam plate to where it just aligns with the roller at the same exact time that the throttle plate begins to rotate. CLICK HERE for a link to the carburetor/fuel pump section for more detailed information."

Here is the link: Maintaining Johnson/Evinrude 9.9 part 1

Scroll down about 1/4 of the way, "Timing"

Paul T
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post #22 of 27 Old 08-17-2012 Thread Starter
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Re: 1981 Evinrude 9.9hp 2str starts but won't run

Thanks for that link. I had found 'Leeroys Ramblings' months ago, but when I tried to go back the link was dead. Tons of good stuff there.

The motor has now started 3 out of 3 tries and it will be put on the boat this weekend. I can wring out these last few problems there. My boat might even leave the mooring and putt-putt up the river; I'm pretty excited. I wouldn't trust this motor to go down river where the drawbridge is waiting... hungrily. By the end of September, I should have a new 4 stroke motor and I can sell this Evinrude.

So, I will look into the alignment of the follower plate vs. throttle position. As it is I have to be very careful to only reduce the throttle so much and no more or the motor will stall. I need to be able to slam it to SLOW and not worry; I can't have it die in the middle of docking.

Ken

Zen Again

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post #23 of 27 Old 08-17-2012
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Talking Re: 1981 Evinrude 9.9hp 2str starts but won't run

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Originally Posted by CarbonSink62 View Post
Thanks for that link. I had found 'Leeroys Ramblings' months ago, but when I tried to go back the link was dead. Tons of good stuff there.

The motor has now started 3 out of 3 tries and it will be put on the boat this weekend. I can wring out these last few problems there. My boat might even leave the mooring and putt-putt up the river; I'm pretty excited. I wouldn't trust this motor to go down river where the drawbridge is waiting... hungrily. By the end of September, I should have a new 4 stroke motor and I can sell this Evinrude.

So, I will look into the alignment of the follower plate vs. throttle position. As it is I have to be very careful to only reduce the throttle so much and no more or the motor will stall. I need to be able to slam it to SLOW and not worry; I can't have it die in the middle of docking.

Ken


Thanks for the feedback. Sounds like you have a little fine tuning to do. Maybe give it a good run while still tied to the dock so the bridge doesn't get you. Assuming the ignition timing is OK, (there may be marks that a timing light will show), and there are no air leaks, and the idle mixture is as rich as you can get it without stumbling, it should idle down from 500 to 750 RPM (I think) If you need more than 2 turns out or it idles unevenly you may have an air leak somewhere. Anyway, I hope it goes well. Once you get it running properly it should last a long time. Mine ran perfectly for 10 years and was still going strong when I sold the boat. You might not need a big fat heavy 4 stroke after all.

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post #24 of 27 Old 08-21-2012 Thread Starter
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Re: 1981 Evinrude 9.9hp 2str starts but won't run

I adjusted the lean/rich setting a little richer and it now runs much smoother and restarts easily. I still can't slam the throttle to minimum, the motor dies at idle.

If the mark on the cam follower is idle, then it runs great at idle. It seems a little fast for idle, but what do I know? Also, if that mark is idle, why is the throttle allowed to go further down?
-----
I got the motor on the back of the boat, but it wouldn't start. Have I mentioned that it doesn't charge the battery? The elect. start was an upgrade and it never got the 12VDC output kit. I depleted the battery severely during the test and tune phase and I only have a little trickle charger (my good one is up at camp).

So, once it was on the boat, I got one crank from the battery and no more.

I had to be towed back to my mooring (in shame!).

I hooked up the solar charger and left it for 2 days.
-----
I went back out yesterday and it started right up, first crank. I ran it for 5 minutes and shut it down; it started right back up.

So except for the idle issue, I'm good to go. I might let the next owner worry about that. Looking at the water I dumped out of my test stand bucket convinced me that four stroke engines are the way to go. Yuck!

Zen Again

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post #25 of 27 Old 08-21-2012
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Re: 1981 Evinrude 9.9hp 2str starts but won't run

Somewhere in the linkage mechanism from the twist throttle handle to the carb butteryfly there must be an adjustment screw or stop. I can't remember what it was on our motor. Nor can I remember exactely what the cam and marker settings were. Unless somebody changed them and it runs all right that would be the last thing I would tinker with. Suggest you richen up the idle mixture until it roughens up then lean it back just enough to smooth it up, run the mixture as rich as you can. Sounds like a good motor if you can find the idle speed adjustment. A good detailed shop manual should show all the proper settings.

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Re: 1981 Evinrude 9.9hp 2str starts but won't run

I tried to richen up the mixture but I got 4-5 turns out and it still ran well. I put it back in all the way and then out 2 turns, that seems to work.

I'll re-read the shop manual (I have Clymer's, I think) and see what it says about the rich/lean setting and idle issues..

Thanks a lot for your help, Paul.

BTW - I worked on it in my back yard; as I pulled each tool out of my shop toolbox, I made sure that I had a tool to do that job onboard the boat.

Zen Again

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Re: 1981 Evinrude 9.9hp 2str starts but won't run

4 or 5 turns out and still running smoothly may indicate an air leak somewhere? Maybe the reason it won't idle slowly? Suggest you check the manifold bolts torque. If snug maybe the gasket is leaking? Perhaps a very thin coat of silicone gasket sealer around the far outer edges. Be careful not to get any around the small passages.

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