1994 140hp v4. Hard starting and intermittent rough idling and dying.

Mrobi

Seaman
Joined
Mar 7, 2021
Messages
61
Will 1 poorly set idle screw cause hard starting and intermittent rough idleI and dying . And horrible build up on the cylinder 1 &3 plugsI have rebuilt the carbs. New fuel filter. New regulator. New coil packs. Timing is spot on. After rebuilding while setting idle screws back to recommend setting i stripped the & 1 idle screw. From 2000 to 5000rpms(wot) it runs perfectly. Thanks
 

Crosbyman

Admiral
Joined
Nov 5, 2006
Messages
6,222
one HAL 9000 opinion...fwiw
POST YOUR MDL #


Yes — on the 1994 Evinrude E140CXERE carbureted V4, that combination of hard starting + intermittent rough idle + dying points me more toward a fuel/low-speed carburetion problem than an ignition problem, although ignition should be checked too.

I'd investigate in this order:

  1. Carburetor low-speed circuits
    • A partially plugged idle/low-speed passage can cause exactly this.
    • The engine may run reasonably once the throttle is opened, yet be difficult to start and die at idle.
    • If one carburetor is affected, the engine can idle very unevenly.
  2. Choke/enrichment system
    • If it is hard to start cold, check whether the electric primer/enrichment system is actually supplying fuel.
    • If it starts only after repeated priming, that's a strong clue.
    • Conversely, excessive enrichment can make it load up and die.
  3. Carburetor synchronization/link-and-sync
    • On this V4, the four carburetors need to begin opening together and the idle timing/throttle relationship must be correct.
    • An incorrect adjustment can produce a very unstable idle.
  4. Fuel supply / air entering the fuel system
    • Check the primer bulb, fuel hose, connections and fuel filter.
    • A small air leak can make the problem intermittent.
    • Watch the primer bulb while the engine is running; if it repeatedly collapses, that's particularly significant.
  5. Ignition at idle
    • Check all four plugs for condition and compare them.
    • An intermittent coil or ignition component can cause an occasional dead cylinder and make the engine suddenly shake or die.
    • A spark-gap test is much more useful than simply looking at the spark at the plug.
  6. Compression
    • I'd do this before getting too deep into carburetor work. Four relatively even readings are what you're looking for.

A very useful test​

When it is running rough and about to die, carefully give it a small amount of choke/enrichment.

  • If it immediately improves: very strong indication of a lean fuel condition — carb low-speed circuit, fuel restriction or air leak.
  • If it gets worse: you're probably not dealing with a simple lean condition.
  • If there is little/no change: ignition or synchronization becomes more suspicious.
Also, if it dies suddenly as though someone switched the ignition off, rather than gradually coughing and slowing down, I'd move ignition higher on the list.
 

Mrobi

Seaman
Joined
Mar 7, 2021
Messages
61
Step #1 is a compression test.----Post actual values here.
Cylinder 1 cold/warmed up. 120/118
3 120/119
2. 119/118
4. 118/116
Surprising the compression fell off a little after warming up. Counterintuitive. But a lot better numbers than the last time I checked compressions about a year ago for this forum. Either a faulty tester or operator error
 

Mrobi

Seaman
Joined
Mar 7, 2021
Messages
61
one HAL 9000 opinion...fwiw
POST YOUR MDL #


Yes — on the 1994 Evinrude E140CXERE carbureted V4, that combination of hard starting + intermittent rough idle + dying points me more toward a fuel/low-speed carburetion problem than an ignition problem, although ignition should be checked too.

I'd investigate in this order:

  1. Carburetor low-speed circuits
    • A partially plugged idle/low-speed passage can cause exactly this.
    • The engine may run reasonably once the throttle is opened, yet be difficult to start and die at idle.
    • If one carburetor is affected, the engine can idle very unevenly.
  2. Choke/enrichment system
    • If it is hard to start cold, check whether the electric primer/enrichment system is actually supplying fuel.
    • If it starts only after repeated priming, that's a strong clue.
    • Conversely, excessive enrichment can make it load up and die.
  3. Carburetor synchronization/link-and-sync
    • On this V4, the four carburetors need to begin opening together and the idle timing/throttle relationship must be correct.
    • An incorrect adjustment can produce a very unstable idle.
  4. Fuel supply / air entering the fuel system
    • Check the primer bulb, fuel hose, connections and fuel filter.
    • A small air leak can make the problem intermittent.
    • Watch the primer bulb while the engine is running; if it repeatedly collapses, that's particularly significant.
  5. Ignition at idle
    • Check all four plugs for condition and compare them.
    • An intermittent coil or ignition component can cause an occasional dead cylinder and make the engine suddenly shake or die.
    • A spark-gap test is much more useful than simply looking at the spark at the plug.
  6. Compression
    • I'd do this before getting too deep into carburetor work. Four relatively even readings are what you're looking for.

A very useful test​

When it is running rough and about to die, carefully give it a small amount of choke/enrichment.

  • If it immediately improves: very strong indication of a lean fuel condition — carb low-speed circuit, fuel restriction or air leak.
  • If it gets worse: you're probably not dealing with a simple lean condition.
  • If there is little/no change: ignition or synchronization becomes more suspicious.
Also, if it dies suddenly as though someone switched the ignition off, rather than gradually coughing and slowing down, I'd move ignition higher on the list.
Ok. After carburators rebuilt. I reset all carb linkages, set screw according and timing the manual. Checked the primer solenoid. Its reads 4.9 ohms. And there was pressure. Did not have a syringe handy to check flow. Will have to do that.
No leaks at the primer bulb
one HAL 9000 opinion...fwiw
POST YOUR MDL #


Yes — on the 1994 Evinrude E140CXERE carbureted V4, that combination of hard starting + intermittent rough idle + dying points me more toward a fuel/low-speed carburetion problem than an ignition problem, although ignition should be checked too.

I'd investigate in this order:

  1. Carburetor low-speed circuits
    • A partially plugged idle/low-speed passage can cause exactly this.
    • The engine may run reasonably once the throttle is opened, yet be difficult to start and die at idle.
    • If one carburetor is affected, the engine can idle very unevenly.
  2. Choke/enrichment system
    • If it is hard to start cold, check whether the electric primer/enrichment system is actually supplying fuel.
    • If it starts only after repeated priming, that's a strong clue.
    • Conversely, excessive enrichment can make it load up and die.
  3. Carburetor synchronization/link-and-sync
    • On this V4, the four carburetors need to begin opening together and the idle timing/throttle relationship must be correct.
    • An incorrect adjustment can produce a very unstable idle.
  4. Fuel supply / air entering the fuel system
    • Check the primer bulb, fuel hose, connections and fuel filter.
    • A small air leak can make the problem intermittent.
    • Watch the primer bulb while the engine is running; if it repeatedly collapses, that's particularly significant.
  5. Ignition at idle
    • Check all four plugs for condition and compare them.
    • An intermittent coil or ignition component can cause an occasional dead cylinder and make the engine suddenly shake or die.
    • A spark-gap test is much more useful than simply looking at the spark at the plug.
  6. Compression
    • I'd do this before getting too deep into carburetor work. Four relatively even readings are what you're looking for.

A very useful test​

When it is running rough and about to die, carefully give it a small amount of choke/enrichment.

  • If it immediately improves: very strong indication of a lean fuel condition — carb low-speed circuit, fuel restriction or air leak.
  • If it gets worse: you're probably not dealing with a simple lean condition.
  • If there is little/no change: ignition or synchronization becomes more suspicious.
Also, if it dies suddenly as though someone switched the ignition off, rather than gradually coughing and slowing down, I'd move ignition higher on the list.
Set all carb linkages, set screws and timing according to manual and prefromed a successful a
sparkplug gap testafter carb rebuild. Checked primer solenoid with multi meter- 4.9 ohms and it has pressure. Did not use all oem parts. Double checked sparkplug gaps. And performed a spark plug gap test. No leaks around the primer bulb. Haven't noticed primer bulb collapsing. Any way to get a stripped idle screw out?
 

Mrobi

Seaman
Joined
Mar 7, 2021
Messages
61
Trying now. Got no 1 carb set screw working again.drilled a small hole trough the plastic into brass insert a little. Then threaded a small screw to it hold it in place while I adjusted it.
 

racerone

Supreme Mariner
Joined
Dec 28, 2013
Messages
39,884
Have battery charged and load tested.----Take starter apart for inspection and ohm test on armature.-----You are pushing the key in and holding it it while cranking it over?
 

Mrobi

Seaman
Joined
Mar 7, 2021
Messages
61
Have battery charged and load tested.----Take starter apart for inspection and ohm test on armature.-----You are pushing the key in and holding it it while cranking it over?
Batteries are on charger. Starter cranks over motor fine. I normally just use the choke at 1st start. But then I'll fumble with it on the water when it's acting up.
 

racerone

Supreme Mariner
Joined
Dec 28, 2013
Messages
39,884
That motor spinning over fast should start right up ! ---So load test the battery.----Take the starter apart for inspection as posted.-----No $$ spent on those simple steps.
 

racerone

Supreme Mariner
Joined
Dec 28, 2013
Messages
39,884
It is elegantly simple to work on these starters!----Nothing to them.----Just 2 bolts to take out.----Scratch the upper and lower parts for correct re-assembly.-----An assistant with 2 knives helps with final assembly.----No need for a shop if you ( neighbor ) have a digital multimeter.
 
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