1965 Evinrude 9.5 - won't start & very weirdexhaust problem

[since1791]

Been reading lots of threads last 2 days & still can't find what's going on with this. Just finished up on: New carb kit, new thermostat, complete gear case and lower unit disassembled-cleaned, all seals and gaskets replaced, new water pump kit, new spark plugs. Got everything together & the engine started up in the test tank a couple times but died after about 35 seconds or so. The powerhead had a good amount of heat smoke coming from it & I don't remember seeing any water coming out of the exhaust port right below the hood in the rear of the motor. 2 very weird things: There were a lot of these little black plastic, rubber or tar-looking particles that looked like sand chunks all over in the test tank & the inside exhaust and water pump was filled with this stuff- a ton of it. I took apart the water pump since I thought it might be the impeller shredded into pieces since this black rubber or plastic stuff could be tied to not seeing an water coming out of the exhaust. The impeller was perfect, along with everything else I could see, with exception to this black stuff everywhere. Ran some grass trimmer wire up the water inlet hose after I pulled the lower unit, per advice from one of the veterans on another thread. Didn't feel anything until I hit something about 2 feet of trimmer wife up into the hose but it seemed normal. Felt like I was possible hitting some kind of rubber grommet maybe? Now the starter rope is completely stuck too- won't budge. The weird thing there is I can turn the flywheel just fine & I pulled the head & spark plugs to see what was going on with the pistons. I move the flywheel & the pistons move back and forth just fine. Didn't have the drive shaft in, not sure if that makes a difference or not. The tops of the pistons had what looked to me to be pretty serious tar action going on that I have to clean but the piston walls look fine so far as I can tell. There was also a lot of nasty looking black grease at the top of the drive shaft when I pulled the lower unit from the motor. Summing up, here's the 3 weird main things that I just can't seem to figure out:
1. No water shooting out exhaust port & tons of those sand-like black particles everywhere in the test tank water, water pump & exhaust.
2. Rope stuck- won't budge, but the flywheel & pistons seem fine
3. Motor only ran about 35 seconds at most and seemed like it was overheating??
Any help-advice is greatly appreciated. Thanks

 

[Daviet]

Re: 1965 Evinrude 9.5 - won't start & very weirdexhaust problem

1. You might try removing the lower unit and the thermostat, try blowing air up the water tube to the block and see if the block is plugged. If you blow some of the black particles out, you might have a plugged block. Maybe you could attach a hose to the water tube and see if water will flow through the block.
2. I think there is a screw driver slot in the top of the recoil starter, can you turn the recoil by hand?
3. I think it would take longer than 35 seconds to overheat the engine, but you need to check the water flow through the block and make sure it flows water properly.

 

[since1791]

Re: 1965 Evinrude 9.5 - won't start & very weirdexhaust problem

Thanks Daviet! You were right about the screw on top of the recoil starter. Got it moving with the screwdriver at the top that you mentioned and it seems to be fine. Blew out all the water passages and didn't notice any blockages. I think at this point I'm going to take it to a service shop to get it timed, carb tuned, pistons cleaned & everything checked over by a professional. This is my very first experience ever with working on an outboard and I've learned a ton; especially from reading the different vets on the forum. But I better get this thing to someone with a lot more experience than me. Still can't figure out what all that black stuff is but hoping maybe the outboard mechanic will see something. Thanks again. I'll post any significant findings after it's checked over and maybe it will help out others. There seems to be a fair amount of these older Evinrudes and Johnsons out there- many vets have commented that it's a faithful little motor that was pretty well made.