1964 3 HP Evinrude (model #3402) Can't get a spark. Please help a newbie.

[swimscubasteve]

I bought one of these for $80. The guy said it wouldn't spark. It doesn't. This is my first motor ever and I'm just starting to learn about small engines. I'm trying to get it working for as cheap as possible.<br /><br />Today I took the gas tank off, the starter puller and the propeller. My first question is how do I get the flywheel off? I have tried using a strap wrench around the flywheel and pliers on the propeller axle/bolt combined with WD40 but I couldn't get it to break free (after trying for about 3 hours and 2 trips to home depot).<br /><br />My second question is, after I get the flywheel off, what do I need to do to make the spark plug spark?<br /><br />Thank you for any advice that you can impart on a somewhat mechanically inclined philosophy major.

 

[rodbolt]

Re: 1964 3 HP Evinrude (model #3402) Can't get a spark. Please help a newbie.

first thing is to buy a service manual. a clymers or seloc from iboats will get you through ok. second is some basic tools. you will need a spark tester. can be homemade. there are several posted on this forum and one or two in the yamaha forum. you will need a compression tester. about 20 dollars at most outlets. you will need a harmonic balancer puller and 3 grade 5 or higher 1/4 20 x about 3.5". you will need some thick washers to use as backups on the bolt heads. a strap wrench should hold enough to remove the flywheel nut. the flywheel is held on by an interference tapered fit indexed by a woodruff key. first order is to insure compression is good, then we can make sparks. once you get sparks its time to rebuild the carb then do the water pump in the lower unit. after all that you will find the old 3 hp is a sewing machine.

 

[Paul Moir]

Re: 1964 3 HP Evinrude (model #3402) Can't get a spark. Please help a newbie.

Welcome to Iboats, swimscubasteve!<br /><br />Have you got the flywheel nut off? If so, you must use a puller that operates on the three screw holes in the flywheel, and pushes on the end of the crankshaft. A cheap automotive 'harmonic balancer puller' works well, but you'll probably need to buy 3 1/4"-20TPI bolts for it about 3 or 4" long.<br /><br />9 times out of 10 bad spark is caused by cracked ignition coils. Fortunately, since they are so very common you can get replacements pretty cheap. Iboats or NAPA 18-5181 is the aftermarket replacement and Iboats wants around $17 each for them. I suggest you purchase some new points and condensors as well - they're cheap to replace and then you'll have a brand new ignition system. The spark plug wires are rarely a problem, but check them for cracks as well.<br />It's also conceivable that the engine wasn't put together properly and the flywheel key sheared at one time.<br />You'll also want a water pump rebuild kit for once you've got it going. Since you don't know it's history it should be replaced. They only last a couple seasons anyway. <br />Without a manual, you are flying blind. If you don't want to buy one, borrow one from the library. You're going to need to torque the flywheel nut, setup the point and coils, etc. <br />Here's a couple sites for you:<br /> 3hp Tune up article 1<br /> Another (even better) 3hp Tuneup article. - although I don't recomend the flywheel removal method.<br /><br />Joe Reeve's wobbly armature plate fix.<br /> <br /><br />Those are excellent little engines, by the way. Once tuned up they run forever.<br /><br />EDIT: Pardon my post collision, Rodbolt!

 

[swimscubasteve]

Re: 1964 3 HP Evinrude (model #3402) Can't get a spark. Please help a newbie.

Yes, I got the nut off, it came off rather easily.<br /><br />What would the BEST manual (easy to read for a newbie) be for my motor?<br /><br />And I had looked at that first article Paul mentioned but I was hoping for a free method to get the flywheel off.<br /><br />BTW, these forums are awesome. I had no idea what a wealth of knowledge could be found here. Thank you again for the quick responses.

 

[rodbolt]

Re: 1964 3 HP Evinrude (model #3402) Can't get a spark. Please help a newbie.

no worries paul<br /> I survived the collision. you probably see more of them tiny mites than I do any more. but that 3hp omc was a running beast as long as ya kept it cool.

 

[Paul Moir]

Re: 1964 3 HP Evinrude (model #3402) Can't get a spark. Please help a newbie.

The very best manual is the factory one. Somtimes they pop up on ebay for a fraction of the price of a reprint, but I only see a '68 3hp there now. You can get reprints from the following places:<br />TheOutboardWizard<br />Mastertech<br />Marine Engine<br />Ken Cook <br /><br />The Seloc one is second. It covers your engine fairly well, and it's not too bad. They're aimed more at the beginner than the factory one naturally, which might be an advantage to you. But since it covers many engines it is somewhat confusing, and there are quite a few outright errors in it. I don't like the Clymers as much as the Seloc.<br />Personally, I think the factory manual is the better bet for someone new to this as long as they have access to Iboats. If there's something that isn't clear in the manual, you can just ask here.<br /><br />rodbolt, I don't know what it is about those little 3 and 4hps that they all try to find me when they're sick. I'll tell you it's amazing to see these engines that have seen 40 years service in salt and are still putting along.

 

[swimscubasteve]

Re: 1964 3 HP Evinrude (model #3402) Can't get a spark. Please help a newbie.

So I will go to the library tomorow and get the factory service manual.<br /><br />Is this what I need to get the flywheel off?<br /><br />here

 

[P.V.]

Re: 1964 3 HP Evinrude (model #3402) Can't get a spark. Please help a newbie.

Ok, I'll suggest this method, (just to get everyone riled up!!!). BTW, make no excuses, many outboard techs (us old ones who will admit it anyway), will back the nut up to the top of the crankshaft threads, then using a brass hammer of a "good" size, while lifting up on the flywheel with your hands, knock the nut fairly hard and ....... watch the flywheel come off. If the flywheel does not come loose after the third "wack", then it's time for plan "B", the puller. OK,,,, everyone now tell me how I'm a train wreck waiting to happen, I can take it!!!!

 

[Paul Moir]

Re: 1964 3 HP Evinrude (model #3402) Can't get a spark. Please help a newbie.

Well, I for one am not going to come after you - I've already made my position clear. <br /><br />swimscubasteve, that's the right sort of thing, but that price is terrible! I purchased mine locally for $14 Canadian, and got a much heavier-duty Lisle one which is capable of handling larger outboard's flywheels.<br /><br />(PS - a quick search showed 'Harbour Freight' has one for $10. It looks a little heavier, but not as strong as the Lisle)

 

[jafa]

Re: 1964 3 HP Evinrude (model #3402) Can't get a spark. Please help a newbie.

Theres the "hang the flywheel , motor and boat from a tree branch and climb in the boat with your partner of choice" method. A similar one involves a few buddies and some beer. posters have claimed both methods having some degree of sucess although you have to check the landing will be soft . I used PV's method , loosened the flywheel nut a couple of turns then put a second nut tightened up to the first which covered the thread and whacked that.

 

[JB]

Re: 1964 3 HP Evinrude (model #3402) Can't get a spark. Please help a newbie.

I have used P.V.'s method on many outboards and other small engines without causing trouble.<br /><br />I used to have a "castle nut" that I made by drilling and tapping a bit of bar stock with a blind hole that fit most crank ends. Spin it tight on the end of the crank, then gently tap it with a big mallet while prying up on the flywheel. Increase "gently" as necessary.<br /><br />The secrets to this method are that you must not mushroom the end of the crank and there must be a little room for the flywheel to move off the taper.<br /><br />Good luck.

 

[swimscubasteve]

Re: 1964 3 HP Evinrude (model #3402) Can't get a spark. Please help a newbie.

OK, so I removed the flywheel and got the shop manual from the library.<br /><br />I also got a pressure tester but I am only reading about 40 psi on both cylinders.<br /><br />What should my next step be to get a spark?<br /><br />Thanks again for all the great help.

 

[Paul Moir]

Re: 1964 3 HP Evinrude (model #3402) Can't get a spark. Please help a newbie.

Hmm.. That compression is too low. Is this a 'push in' type tester or screw in? Is it new and/or trustworthy?<br />If so, did you pull the starter rope a few times with the tester in? With these small engines, a lot of testers won't top out until 4 or five pulls.<br /><br />Forget about spark for now and lets see what we can do about that compression. You can just place the flyweel back on and thread the nut on hand tight for checking compression - there's no need to torque it down until it's going to be started.

 

[swimscubasteve]

Re: 1964 3 HP Evinrude (model #3402) Can't get a spark. Please help a newbie.

I just turned the flywheel about 6 times to check the compression.<br /><br />The tester is a screw in type from harbor freight.<br /><br />How tight should I screw it in? And the repair manual mentioned testing it while it was warm and with the throttle at full. I guess I'm not really sure how to check the compression.

 

[Paul Moir]

Re: 1964 3 HP Evinrude (model #3402) Can't get a spark. Please help a newbie.

Ok, did you turn the flywheel with your hands or with the pull start? If it doesn't happen fast enough, it won't read right. <br />Warm and full throttle make very little difference (if any) on a small 2-stroke engine. Also, all compression guages are a little different so don't take any reading as an absolute. Even things like atmospheric pressure and altitude are going to make a difference.<br />That said, I've seen 3hp engines running with as little as 55psi per cylinder by my gauge. But it was pretty difficult to start.<br /><br />I take it your guage has a little o-ring on it? If that's the case it just needs to be finger tight. There's another type of guage that doesn't thread it - you have to hold it in. Those are usually horribly inaccurate.<br /><br />How do the coils look?

 

[swimscubasteve]

Re: 1964 3 HP Evinrude (model #3402) Can't get a spark. Please help a newbie.

I have now hooked it up with teh pull start. It is the type with an o-ring. I cranked it down real well.<br /><br />Do I need the other plug in while I am testing?<br /><br />What should I be looking for on the coils?<br /><br />Thanks for all your help Paul and please excuse my ignorance, I'm a begginer

 

[Paul Moir]

Re: 1964 3 HP Evinrude (model #3402) Can't get a spark. Please help a newbie.

No problem at all! It wouldn't be much of a site if everyone already knew how to fix their outboard. <br /><br />You do not need the other plug in while testing. It'll make no difference.<br /><br />How does the insulation (plasic) on the coils look? Any signs of cracks, etc? Also, what colour are these coils (plastic part and metal part)? There were many designs and some are better than others.

 

[swimscubasteve]

Re: 1964 3 HP Evinrude (model #3402) Can't get a spark. Please help a newbie.

There were no cracks on the coils and one was green and one was blue.<br /><br />Should I worry about the compression?

 

[Paul Moir]

Re: 1964 3 HP Evinrude (model #3402) Can't get a spark. Please help a newbie.

You should definitely check it before proceeding!<br /><br />The green & blue coils sound like replacements. I take it these are the solid plastic ones and not the clearish plastic? They might be all right. They will crack too, but they'll be really thin cracks and not the big gashes you often see in the older coils.

 

[swimscubasteve]

Re: 1964 3 HP Evinrude (model #3402) Can't get a spark. Please help a newbie.

I checked the compression but only got about 50 on each one?<br /><br />Could I be doing something wrong or am I in more trouble than I originally thought?