1996 130HP Evinrude PowerPack test question

A

aok47

Seaman
Joined
Apr 18, 2004
Messages
53
Hey guys,
On a recent trip i was cruising at 5000RPM when motor all of a sudden went into SLOW mode (no audible alarm, no warning lights on system gauge), ignition off, start again and no problems back cruising at 5000RPM. Over the space of running the engine for about 1hr with multiple start stops between fishing spots it went into SLOW mode twice.

I've since checked spark plugs & leads and they were ok.

Performed a PowerPack Output Test (per service manual) and results varried between cylinders, #1 @ 135V / #2 @205V / #3 @140V / #4 @203V
So 2 of them tested <150V. Manual reads like i should either get >150V or nothing, it doesnt tell me what to do if i have Voltage but its <150V (i may not be reading it correctly?)

Appreciate any help with this issue... i hate intermittent issues :-(
Cheers
AK
 
A

aok47

Seaman
Joined
Apr 18, 2004
Messages
53
Any suggestions on what i should do or check next?
Appreciate your help
AK
 
A

aok47

Seaman
Joined
Apr 18, 2004
Messages
53
Incase anyone else comes across this thread in the future, i think i solved my problem.

So... went through the Troubleshooting Sequence Chart just to make sure i hadn't missed anything
Started with Total Output Test -> I had good output from 3 of 4 plugs which then led me to -> Stop Circuit -> some spark present so -> Sensor Coil Test yielded no reading so -> Output Test which showed higher than 0.5V so -> Power Pack test which i had done originally.

I replaced the Power Pack with a spare second hand power pack i had and redid the Power Pack test, viola... >150V across all plugs!

Time on the water will be the final validation step seeing it was an intermittent problem to start off with.

cheers
AK
 
A

aok47

Seaman
Joined
Apr 18, 2004
Messages
53
Finally did the water test.
After about an hour of cruising at varying RPMs the dreaded SLOW mode kicked in again (no alarm or light on the tacho), switched off and started again, after a little while same SLOW mode (no alarm or light on the tacho).
After spending half hour at the dock i went back out and went on about a 4mile run before SLOW mode kicked and this time there was the audible alarm and HOT light came on the tacho...

Tested the overheat circuit to the tacho - works
Tested the temperature switched - open & close per manual

Appreciate any help, this is doing my head in :-(
AK
 
R

racerone

Supreme Mariner
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Dec 28, 2013
Messages
38,411
The S.L.O.W. system is also triggered by an overheat condition.----I would look at the water pump first.
 
A

aok47

Seaman
Joined
Apr 18, 2004
Messages
53
racerone said:
The S.L.O.W. system is also triggered by an overheat condition.----I would look at the water pump first.
Click to expand...
If i've got a steady flow of water out the tell tale do you still think the water pump might be at fault?
I'm not set up to drop the leg so i'll need to take it to a mechanic
 
C

Crosbyman

Vice Admiral
Joined
Nov 5, 2006
Messages
5,647
is this a salt water engine ? a good tell tale is a good start but... heat could accumulate in parts of the engine due to internal blockage from accumulated mineral deposits in the water passage ways . defective thermostat ?

checking the water pump impeller is certainly the easiest thing to check for wear or !! broken fins which could have worked themselves up into the powerhead.. hopefully not. How long ago was it replaced ? Is this a new to you engine ??
water flow could be low with fin parts just stuck in the pump outlet .

While the tell tale may seem ok that is not a certainty that ll is well inside.

Do you have IR temp scanner to see if any specific areas is hotter than the rest . IR scanner go for $20 -$25 these days (cheap toll to have)

Try touching .. is one side burning hot and the other ...less hot ? If so this could indicate circulation issue .
 
Last edited:
R

racerone

Supreme Mariner
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Dec 28, 2013
Messages
38,411
On many motors the water that comes out the tell -----DOES NOT GO THROUGH ---the block..--A wise owner would monitor how quickly water comes out after start up.----A water pressure gauge also helps monitor pump condition..----So in short a healthy tell tale does not always mean that motor is cooling properly.
 
ct1762@gmail.com

ct1762@gmail.com

Ensign
Joined
Jan 17, 2019
Messages
933
fyi the temp switch test isnt simply if its opening and closing. they key is at what temp? of course the next step here would be (provided you are positive the motor isnt overheating and have checked condition of the thermostats) to DISCONNECT and ground the white wire at the pack.
 
A

aok47

Seaman
Joined
Apr 18, 2004
Messages
53
Update
I dropped the leg and opened up the water pump, everything in excellent condition including the impeller.
I pulled off the cylinder heads and found alot of build up in the water passages (right photo is before cleaning left photo after) so cleaned both side, new head gasket, new thermostats and seals. Zipped it all together and tested on muffs.
Alot better flow and pressure out the tell-tale (I realise this isn't the be all end all). Took it out on the water for a test run, starboard side running 135F compared to Port 108F at 4500RPM. No alarms
Get home and flush motor on muffs and overheat alarm went off at 153F (port), 149.5F (starboard). I have attached thermocouples to the cylinder heads near the thermostats so I can verify temps.
What I also noticed was there wasn't a steady stream of water out of the small hole in the leg near the starboard side water pickup. It was an intermittent pulse.
Should I be concerned?
 

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kbait

kbait

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Water muffs are good for testing if a motor is running.. but not good for diagnosing cooling system. Barrel or lake test and check temps..
 
C

Crosbyman

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that is just a cavity drain to let water out to prevent the freezing temperatures from cracking the LU...

nothing to worry about other than running a pipe cleaner to keep it open all the time to do it's job of draining the cavity inside the LU.
 
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