1989 Evinrude 200 not reaching W.O.T. after 20" conversion

[Motv18]

Thanks racer, was wondering. Thought more oil level sender like on some Yamaha.

Whith that op your back to tracking fuel and time.

[jaymalyon]

Slam into a wall to me sounds like a limiter is active. The sputtering and stuff would be it dropping cylinders.

Check the buzzer to see if it works or has been disabled. And it’s probably related to the oil delete. One of the sensor tie offs or wires not terminated correctly sending it to limp mode.

Someone else will will have to walk you through though one of the few things I haven’t messed with. Other then finding them with it done wrong.

Buzzer works and the oil delete was done by an Evinrude shop 10 years ago. I didn't know much about the oil injection system at all back then and figured it was easier to just eliminate it.

[jaymalyon]

Oil delete you just need to plug oil fitting on pump and disconnect the wires coming from pump, and mix at 50 to 1. Slow should hold engine to 2500 however. Since you have had ignition off have you checked wire color coding to the coils?

Yes I have double checked the coil wires with the factory service manual in front of me. They are good to go.

Having some trouble tracking down the correct supply and recirculation lines for the carbs. I'm going to clean the hell out of all the T connections and the fuel manifold, clean the lines the best I can and test it out this weekend.

[Motv18]

Heh, hers an old one. Is the intake on the cowling clogged with a mud dauber nest.

[jaymalyon]

Heh, hers an old one. Is the intake on the cowling clogged with a mud dauber nest.

Haha I don't think so, but now I'm going to pressure wash it while I got it off just in case!

[jaymalyon]

Welp, I'm almost embarrassed to post this, but I think I found the problem. I replaced this filter during the midsection swap and it appears I put it on ass-backward. Sounds like I don't need it anyway if I already have a Racor filter upstream.

I'm thinking this definitely is creating a restriction. Hopefully, I haven't damaged my fuel pump....or worse, running lean trying to get to full throttle.

Also, managed to break off one of the nipples on the primer so now I'm stuck waiting on parts before I can test it out. I wanted to upgrade it anyway to the newer style that you can spray engine tuner directly through it.


Double checked my throttle plates and found something interesting. With the throttle lever full wide open on the dash, my butterflies are not getting 100% straight. Kind of hard to see in the pics but there is still a good 10-15% of travel if I move the cam by hand up top. In other words, my throttle cable is not moving the linkage enough to bottom out the wot stop screw. I'm guessing it needs to?


So the updated plan is trash the ass-backward fuel filter, replace carb fuel lines, replace primer fittings, adjust linkage and then go fast.

[racer]

Your cam linkage is missing the outer part of the roller. Replace and it will open throttle plates more.

[jaymalyon]

Your cam linkage is missing the outer part of the roller. Replace and it will open throttle plates more.

Wow just found a good picture of one and I sure am. I would never have noticed that. Thanks for pointing that out.

[HaulNbass]

Fuel hose w/liners in them are usually shiny grey color, made by sea choice think, and are not good in my opinion, check the fuel pump pulse hose if it’s got a liner, and listen to mrichartz,motv18, they are definitely in the know!!!

[jaymalyon]

Fuel hose w/liners in them are usually shiny grey color, made by sea choice think, and are not good in my opinion, check the fuel pump pulse hose if it’s got a liner, and listen to mrichartz,motv18, they are definitely in the know!!!

Hey we are neighbors! I live in Smyrna too.

No grey hoses for me. I have replaced all the fuel lines with BRP USCG approved fuel line. 10-4 on listening to the voices of reason. Lots of great info here.

Had to order all new float bowl gaskets where I opened up my recently rebuilt carbs to clean the jets again. Got everything put back together over the weekend only to find all the carbs were leaking. I guess the gaskets are only good once? I thought I could get away with it because they are brand new, but doesn't seem to be the case. Stuck waiting on parts again...

Should be able to test it out this weekend if all goes well.

[jaymalyon]

Got the chance to get the boat out this morning. No Change in performance at all. Still will only get to 3900 rpms. All the fuel lines have been replaced, in line filter eliminated, cam roller replaced, and carbs have been cleaned and double checked, with new gaskets.

I reved the motor in neutral up to 5,500 rpm no problem, but it will not get there in forward gear. Running out of ideas here.

[Motv18]

Well, since you hit 5500 after putting it together the it dropped second run.

We might start from the top, new compression test to looking for lose wires and cdi testing. New part might have broke

[jaymalyon]

Well, since you hit 5500 after putting it together the it dropped second run.

We might start from the top, new compression test to looking for lose wires and cdi testing. New part might have broke

I guess bad new parts are not out of the realm of possibility. Just went through 3 "new" steering boxes with my truck.

I'm pretty convinced it is no longer a fuel issue although I haven't checked WOT fuel pressure. I wouldn't think I would hit a consistent 3900 rpm every single time if it were fuel though. Wouldn't it be a bit more intermittent than that? Surging, bogging, sputtering, etc?

I even removed all the coils and wire brushed the ground contact on the block today. Just so strange that it ran 5500 rpm one time and then stopped. Frustrating.

[Motv18]

Yep. Even worse if you went through and found a busted tach. But it’s probab like the fuel filter. Something unplugged or such like the fast start you unplugged while doing timing or checking it. Or a wire left off.

[powerabout]

Carb linkage loosened
Mainjet backed out till hit drain screw
Carb side cover lose