1973 Evinrude 9.5 Needs awakening - Won't Start

[skyzend]

First post to iboats ... here's the story ...
I inherted back a 12ft car topper, partial trailer, and 9.5 evinrude thats only been run maybe twice in 25 years. I had this engine and boat/trailer when I was 14 and it was loaned away to an x-brother-in-law and I just got it back.
The trailer is in bits with no axel and winch post, the boat is good but the motor mount is totally rotted. (Took it off with myfingers).
Now for the motor ... it appears to be in descent shape and I am slowly working my way through the steps in the "awakening a sleeping motor" article.

This post is basically to track my steps and provide my experiences getting this whole combination back running, getting to and on the water

The fuel pump had been dismantled and re-installed at some time, I think, as it appears to not have been done properly. It failed the reverse blow-through test before I even started. I took it apart and rebuilt using instructions I found here: http://www.sschapterpsa.com/ramblings/Rebuilding_fuelpump.htm
Forward and reverse blowthrough tests now pass

I have purchased a Clymer shop manual for now, waiting for it in the mail, will look into a proper evinrude manual later.

Tried to see if things would start but its a no-go.
I checked the plugs, they are in pretty good shape, a little dirty but not fouled, they were a bit wet indicatiing some fuel is making its way here. I checked for spark with the plugs out and there is a nice spark on both plugs.
I also did a compression test with a really cheap compression tester and I have compression on both cylinders but cannot tell how much .. they do seem equal though and the guage jumps to over 50 psi equally on both cylinders.

Next up ... carberator rebuild, lower end oil relacement, and to check/replace the water pump/impeller, if I can figure out how to do this???
Also noted that the stop button is a nylon threaded piece that is broken and needs to be replaced. But since I see spark on the plugs the broken button is still functional and not shorting out.
I will replace the plugs too as the existing ones are 1973 originals.

As for the boat, I purchased new hardware and 3/4 plywood for the mount, along with a new drain plug which was missing. The original hardware was rusted away to nothing.

The trailer is stripped down and ready for a quick sand and Tremclad, I picked blue, but will give a primer coat to start.
I have a new axel/spring assembly on order along with a winch post and cheap fenders. I've purchased new light system which needs installation as well.
Still required is a saftey chain and a new hitch. This could be tricky as the original hitch was bolted on with 2 welded seams(???). Also need new bolts for all the roller hardware brackets as these were all very rusted.

I'll keep you all posted on how the re-conditioning exercise goes.

 

[tashasdaddy]

Re: 1973 Evinrude 9.5 Needs awakening - Won't Start

lots of good info here. http://forums.iboats.com/showthread.php?t=299680

 

[crxess]

Re: 1973 Evinrude 9.5 Needs awakening - Won't Start

Best of luck on the project! I just purchased a 9.5 to upgrade the 6hp currently in use. Haven't even opened the shipping box yet.

Things I have learned so far in my ventures on the 6hp.
Proper carb rebuild is top of the list on long sitting motors.
Spark needs to be able to jump a decent(1/4+) gap.
Fuel pressure steady. Double Check everything from tank vent to carb.
Always replace an unknown water pump.

I'll be back to see how your project is going and hopefully learn more.

 

[Rick.]

Re: 1973 Evinrude 9.5 Needs awakening - Won't Start

Sounds like a project for sure. I would suggest you get the flywheel off and have a look at the coils and points. I would probably just order new points and condensers so you can eliminate that as a potential concern. I have the same year motor and just got it running last winter. I'm very fond of it and it runs well. My only problem is I hardly ever get it out on the lake. Rather than buy an OMC kill switch you may consider replacing it with a lanyard kill switch. A very easy thing to do as it fits in the same hole. Best of luck. Rick.

 

[skyzend]

Re: 1973 Evinrude 9.5 Needs awakening - Won't Start

Ok folks ... for those that are following along ...

I was promosed the axle for the boat trailer on Friday, not ready but was told the work order is for Monday (today) so I just need a little more patience.

The carb rebuild kit is on order ... to be here on Wednesday ... I hope

In the mean time, I took off the carb, nasty thing all but 1 screw is easy ... I had to buy a big wide screw driver to get the 5th screw out. I did not want to muck up the head with cheaper regular sized driver as I knew once that happened I am screwed. (figuratively and literally).

Without a kit I took the carb apart and had a look see and it was really clean ... almost like new clean ... and it likely has not been rebuilt before as it still has the cork float in it. Anyway I sprayed alll the ports and openings with carb cleaner and blew dry. I re-installed over the old gaskets.

I cleaned the plugs and had another crack at starting. Success ... sort of.
I could only get the thing to start in gear with a little more gas ... beyond what the idle provides. Every time it went slow it cut out. So there is some work to be done here. I know the idle adjustment was way out but I am also suspicious that at low idle speed RPM there is not enough juice to create a quality spark if at all. I've had some experience with this and car engines so next up is new plugs ... I know this should help a lot. I cannot believe the wires are bad as they look so darn good but I would be a fool to totally forget them as a root cause.

One thing that this proved though is that my fuel pump rebuild exercise worked as a steady fuel flow provided enough to start the engine. The pump bulb was solid after running the engine for a short 20-30 second period. which indicates that I am actually drawing fuel from the tank.

I should digress a bit here and give some history on this engine. (boat and trailer too)
I used it as a kid over about 3 summers, It was not abused ... just weekend stuff so not a huge amount of hours were put on it. Since then it was borrowed and used 2-3 times max and stored in sheds over a period of about 20 years. Its been moved from Toronto to North bay, Ontario to NovaScotia and back to Ontario during this time until I got it back along with boat and trailer. The trailer was dismantled as the movers along the way would not take the trailer as a single item. So there you have it ... no wonder this motor looks new under the cover. The boat was always stored upside down so the wood motor mount rotted away leaving the inside of the boat in like new condition. I just wonder about the seals ... I'll find out soon enough.

I changed out the lower end oil ... I remember doing this as a kid and would bet the oil was the stuff I put in it during about 1976. It was a really clean milky butterscotch colour indicating that there may be some water in it ... but still really clean. I'll keep an eye on this after it goes into the water for its first try.

Thanks for the kill switch recommendation. I'll consider this when the time comes as there is still lots to do. Look for another update in a couple days.

 

[crxess]

Re: 1973 Evinrude 9.5 Needs awakening - Won't Start

Just got my new to me 9.5 running.

I'd suggest going back to the carb once more. With the fuel drain plug removed, there is an orifice plug(high speed jet) deep inside the opening. Hard built up can block it solid.
I used a set of welders files to clear this passage and open the orifice to original size.
Also with the throttle held open you can see 3 tiny holes inside the throat. Make sure you have good spray from all 3. This is the low speed circuit.
As I understand, there is no sealed foam float to replace the O.E.M. cork float. Just original replacements. I am looking into something that can be modified.

If you have spark to run at speed, idle should work. More likely lack of fuel as lower manifold vacuum.

Start with your lean rich set around 2 1/2 and it should run. once warm, place in gear and start closing(lean) slowly. allow to stabilize and continue. It should sneeze. Back out a little to settle/smooth out. should be close there. Mine settled around 1 1/4 out.

Good luck

 

[skyzend]

Re: 1973 Evinrude 9.5 Needs awakening - Won't Start

Not much work done this week.
Shop called this morning and my axle and springs are ready.
Looking to pick up my car rebuild kit today as well.
My blazer needs brakes and cannot be driven so I need to do this tonight.
Without it I cannot pull the trailer.

Trailer rebuild starts tomorrow AM ... early, I imagine a few trips to collect nuts and bolts.
I'll rebuild the carb with the new rebuild kit tomorrow and pull the flywheel to have a look at points and check the gap ... I think its supposed to be around .020, I got this from another thread. I will also get around to cutting a motor mount and installing tomorrow as well.

The target is to be on the water by Sunday AM to do a final fine tuning and idle RPM set on the motor. If all is well may I'll do some fishing too. (Only the water pump could spoil things.) I also have to check the seals in the boat to see how they have faired over the years.

Question: For anyone and CRXESS ... what spark plugs are you running in the 9.5. I've seen different specs from different sources ranging from J4C, J6C to J8C (Which I refuse to believe). The motor currently has J4C installed but Evinrude web sit lists J4J-WE and AC-M42K on their web site exploded diagram which maps to champion J6C on the Championsparkplug site. I've seen charts that list all Evinrude plug types that list J4C as the correct replacement. Now i'm puzzled ... this will make a difference in getting a correct setup.

Aside: For those interested, I do all my own car repair as well. My Blazer is currently headed for 400,000KM ( just barely broken in )so I think I'm doing something right. For advice I use www.automotiveforums.com. This site is very much like iboats with many extremely helpfull contributers such as yourselves.

 

[kbait]

Re: 1973 Evinrude 9.5 Needs awakening - Won't Start

J4C will be fine.
I take it that you've been running the motor for 20-30 seconds out of water, since the only thing that could spoil sunday is a bad impeller. Well, my friend, you may have ruined it by running it dry. They'll heat up and melt the edges quite quickly when run for even a brief period. Don't start it again until it's in some water.. enough to submerge the impeller.

 

[skyzend]

Re: 1973 Evinrude 9.5 Needs awakening - Won't Start

I guess i need to expand on my last post.

I have run the motor 20-30 seconds ... and yes it was in water, actually in a garbage pail. I can only get the motor running at high RPM and this means in gear ... in a garbage pail ... with the propellor on ... scary, so I chose not to go any farther until some of the other important tasks were looked after.

No I don't know how good the impeller is as I have not checked it. The motor was never run long enough for the thermostat to open so it is impossible to know if the impeller will even draw into the engine casing.

Even if the impeller is working now ... the motor is so old and has been dry for a very long time. I am optomistic but still expecting the impeller to crap out in a very short period of time ... It definately will need replacing but it may surprize me. I will replace it between now and next season if not sooner, Its just not on the "A" list right now ... this may change.

Lastly ... I do have a trolling motor (never mentioned this) and will take this along on the maiden voyage ... haha ... so if things go sour along the way I will not be left up the creek without a paddle ... and yes i do carry a paddle bailer etc.

I would still like to exactly know what the sparkplug spec is for this engine. "Do just fine" to me doesn't tell me much more than that they will work. I know this, thats what was in the motor and they have been operational.
So some help is still requested ... thanks.

 

[crxess]

Re: 1973 Evinrude 9.5 Needs awakening - Won't Start

J4C - General usage
J6C - mostly Trolling (hotter plug)

Your motor should Throw water from the leg opening almost instantly when started.

Throttle wide open only to get started points to a clogged high speed orifice. just behind the drain plug. Clean with small wire.
Runs but will not idle points toward plugged idle passages, just behind the low speed adjusting jet. 3 Tiny holes up to the throat area.

 

[skyzend]

Re: 1973 Evinrude 9.5 Needs awakening - Won't Start

For those following along ...

Family plans got in the way of my plans all weekend so did not get on the water at all Getting the motor further along will have to wait.
Thanks CRXESS for your input, I now have the carb rebuild kit and will clean things properly emphasizing the areas that you pointed out.

What did get done... I got the trailer de-rusted ... took about 5 hours with a drill and steel brush bit. Lots of pitted steel but generally a good job and a reasonably safe trailer frame(still). next went 2 coats of rust primer and 2 coats of blue paint ... looks nice.
I installed new springs and axle which fit perfectly to the frame and the tongue was installed with new hardware for the "tilt" mechanism. still have some rollers to install and lighting is next. And still to go is the coupler (I cut the old rusty one off) and new fenders. All in all I am a lot closer to having all the "A" list stuff completed on the 3 projects (boat, motor, trailer).

 

[skyzend]

Re: 1973 Evinrude 9.5 Needs awakening - Won't Start

Ok so the projects are moving along ... but still not in the water yet ... too many distractions.

1. The boat motor mount transum which had rotted away has now been replaced ... so the boat is ready to go.

2. The trailer is done with new lighting and registration/plates. I still have a couple of things to finish though. The wheels are rusted and look terrible compared to the nice trailer job. I have some white paint ... just need to finish the rims. The winch mount is 2x3 tubing and is open at the top .... ready to gather rain water ... I need to weld a cap to keep water out. And then I'm done.

3. Now for the motor. I took another crack at the rebuild making sure the idle ports were open. I used quite a bit of carb cleaner and compressed air and am sure the passages are clean and open. I had a high pitched whistle from the ports when I pushed air through.

I still had trouble starting and idling. Again I was only able to get started with a heavy throttle (not full). As things warmed up I was able to throttle back almost to an idle. It eventually quit after several minutes and then I had a hard time starting again.

I did not check the high speed as good as i should have. I need to do this again and also check the spark plug gap. I checked the gap but not properly ... i kind of guessed as my gap guage only goes as small as .035 and I need to have .030. I have bought a new guage and will double check the setting tonight.

Lastly my manual says to start with 3/4 turn on the idle valve and adjust outward allowing 20 secs between each 1/4 adjustment. I will try the 2.5 turn and adjust inwards ... with the liklyhood that it will settle at about 1.25 turns.

The good ... I had a heavy spray from the water impeller which only got more steady once the thermostat opened up a bit.

I have yet to have a look at the points as I am debating on how to pull the flywheel properly. Keeping the flywheel steady while removing the nut has me a bit confused. I do not own the apropriate tool which locks into the geared underside. I am thinking also the possibility of using some metal posts inserted into the holes on the flywheel top and a prybar between them to hold things steady. This should work and not damage anything.
Also I have a harmonic balancer puller but the holes on the flywheel top are too far apart. I am hoping that there may be some holes under the centre washer plate. The exploded diagram on the Evinrude site suggests that there are 3 holes under there. If there are I'm OK but I need to get the nut off first.

Getting close to done

 

[crxess]

Re: 1973 Evinrude 9.5 Needs awakening - Won't Start

Flywheel - a 1"wide ratchet strap works well. You need to pick a good spot for the ratchet assembly to rest to hold things still.

 

[Rick.]

Re: 1973 Evinrude 9.5 Needs awakening - Won't Start

Make sure to re-gap and clean your points or better yet just replace them. Acetone or lacquer thinner and gap to .020 exactly which I found to be important. I have been able to remove the flywheel nut on my own with a good old fashion bear huge but the bar method is better for your ribs. My 73 runs like a champ but I am not sure why yours is hard to start and idle. Perhaps the points will be the remedy. I also put new coils in mine even though the old ones worked but they were cracked. Rick.

 

[skyzend]

Re: 1973 Evinrude 9.5 Needs awakening - Won't Start

I was puzzled as well until ... I regapped the plugs properly.The existing gap was a little larger than the required .030.

I read somewhere that the gap affects the timing, a little too wide and it advances the timing a bit. A little too narrow and the timing retards.

Anyways with a perfect .030 gap and 2.5 turns on the slow speed idle she started right up on the second pull. The idle was a little rough until I made some adjustments. I ran it until it was warm and the thermostat opened fully and set a comfortable idle speed. By the way the slow speed idle ended up at aprox 1.25 turns as you guys predicted.

All is good for now. I have to keep an eye on the water pump output. After running I see quite a bit of "black" in the water. I realize much of this is just exhaust and some soil that was in the bottom of the garbage pail when I started but some maybe from the impeller rubber. I wouldn't be surprized if it slowly started to fail given the age. Actually I fully expect this as its only a matter of time.

I'll take all your advise and get to examining the points as I'm sure new ones will make the motor perform better. Idle is still a little rough at times and I'm sure its "points/condenser/coils" related.

So now a little work on he trailer wheels, and the boat needs a scrub down as there is much "light green" oxidation on the seat benches from the original aluminum paint. This comes off on your clothes and I'm good to go.

Thanks for all your help. It was so valuable. I know that I would have had a more difficult time without the encouraging and accurate comments and feedback. Cheers!!!

 

[skyzend]

Re: 1973 Evinrude 9.5 Needs awakening - Won't Start

I have a package of parts awaiting at home, I hope the order is complete as I will have no recourse if it is not.... there's a story ...

I checked out a couple of "googles" top parts supplier hits to see what a reasonable cost and availability would be. I decided to use:
www.bestboatparts.com

This is a professional looking web site.
No real complaints as I did a search to see, Only 1 guy I could find has had a problem with a partial shipment, anyway ...

I ordered my $90 worth of parts and the order shows up on the web site as Approved. Their track page doesn't work. For 2 weeks the same thing. The order is not "picked" as there is a column for this ... just approved .... which I take to mean they have my money. I try calling the 1-800 number (daily) and each time I get shunted to an anouncement that they cannot take my call .... for 2 weeks this goes on.

Well Monday my order disappears from the web site all together.
I send a polite email to please let me know one way or another if I should just go away or be patient. Again no response ... (like I really expected to get one at this point). Well its Thursday and at least some of the parts have arrived ... I hope the complete order as that was the shipping condition ... ship complete. The online order record probably disappeared once the order was shipped.

Bottom line is that this company probably did what they set out to do and what I requested them to do. However, I had zero communication/response either via email or via 1-800 calls. I was in the dark and was about to duplicate the order elsewhere at additional cost.

Even though I have parts delivered I will not use this company again.
I was very pesimistic that I would receive either my order or my money again.
And zero way of communicating with them.

Just a heads up for anyone else who might be looking to do business with these folks.

Well , back on the tracks now ... looking at getting everything ready for Saturday morning where we'll see how well the timing/contacts/condenser/magneto upgrade works out.

 

[skyzend]

Re: 1973 Evinrude 9.5 Needs awakening - Won't Start

Sorry for the out of order posts but I thought I had posted this update ... i guess not.

I had the boat motor on the lake about 1.5 miles out and the motor quit on me ... had to use the trolling motor to make a slow path home.

At home I took off the flywheel. I opted to put a couple of bolts into 2 of the outer flywheel holes. Then leveraged the 2 bolts with a pick-axe to steady the flywheel while I used a torque wrench to remove the flywheel bolt. This was the easiest solution. Once the bolt and washer was off the 3 bolt holes for a puller were exposed. I used #5-Steel bolts in the holes and a harmonic balancer puller to remove the flywheel.

Underneith I found very cracked up magnetos that were barely holding together. These needed replacing. points needed to be regapped. and the "lubrication wick" was elongated to the point that it was interfereing with one of the points.

I opted to replace both magnetoes points condensers and the lubrication wick. Off to order the points on line which brings me to my previous posting

 

[skyzend]

Re: 1973 Evinrude 9.5 Needs awakening - Won't Start

My luck must be running real low.

Got the shipment but only 1 magneto coil.
I ordered and paid for 2.
I sent an email ... but have not heard a reply from any of my emails.
Phone calls a a bust too.
I can only hope that they reship the missing coil.
I think I will try to order the missing coil locally ... and pay again at probably double the price. Buut at least I will have it right.

Still angers me that I probably got ripped off.
Last timne the shipment left on a Friday and arrived on Thursday. I'll wait that long to see if anything turns up, if not I place a new order.

 

[skyzend]

Re: 1973 Evinrude 9.5 Needs awakening - Won't Start

Ok time to put this thread to rest ... have done quite a bit of work since last year.

Parts that were short shipped never came ... lesson learned.
I bought another magneto coil from a store on ebay along with a fuel pump rebuild kit.
From a different store I bought a lanyard style stop button.
All arrived on the same day. Prices were excellent. Shipment from USA to Canada took 9 days including a major holiday weekend.
I guess an ebay reputation is something that Vendors try to maintain in good standing.

Anyways, Replaced coils, condensors and points. Regapped points at .020".
Checked the fuel pump with plugs out pulled the cord and a good fuel flow was seen so I decided to pass on the fuel pump rebuild for now.

Ran up the motor in my garbage pail setup and got it started and idele settings adjusted ... ready to go ...

Took it on the lake and went for a 25km tour.
Motor ran OK but have a little issue with power at wot.
I'll start a fresh thread for this.

Still a couple of things on the todo list. But they'll get done in do time.
Side running lights on trailer were installed upside down ... need to be flipped over so bulb doesn't work against gravity and drop out.
Trailer Wheels need to be painted.
Winch post is filling with water ... needs drain holes an a cap.
Winch post needs a Bow "roller-Stop" installed.

Have a nice summer ... I'm goin fishing.
Boat needs a bow "whinch loop" installing.