2002 60HP Mercury Big Foot Will Not Start - Old Gas

[ErnieMac]

Please Help!!
I never had a boat before, and I bought a 16 ft deep hull with built in fuel tank, knowing that I would not use it for a couple of years (until I retired), but the price was right and it was everything I wanted. Finally retired, and now the motor will not start…..my thinking is old gas. After many attempts to start, it will just fire for a couple of seconds then stop. when it does, it smells like old skunky gas. I siphoned out gas, (all that I could get out, gas gauge showed less then 1/8 tank. I put in a can of sea foam, and put in the appropriate amount of Esso Supreme 91 octane (up to 10% ethanol). Pulled plugs, and they are not wet. Removed gas line from tank, and tried feeding out of clean gas can with new straight gas, but still no start. I’m assuming the motor fuel system is compromised, but cannot find a schematic of the fuel system in order to start disassembly and inspection of components. PLEASE, ANY HELP or SUGGESTIONS WOULD BE GREATLY APPRECIATED!!

 

[ErnieMac]

Please Help!!
I never had a boat before, and I bought a 16 ft deep hull with built in fuel tank, knowing that I would not use it for a couple of years (until I retired), but the price was right and it was everything I wanted. Finally retired, and now the motor will not start…..my thinking is old gas. After many attempts to start, it will just fire for a couple of seconds then stop. when it does, it smells like old skunky gas. I siphoned out gas, (all that I could get out, gas gauge showed less then 1/8 tank. I put in a can of sea foam, and put in the appropriate amount of Esso Supreme 91 octane (up to 10% ethanol). Pulled plugs, and they are not wet. Removed gas line from tank, and tried feeding out of clean gas can with new straight gas, but still no start. I’m assuming the motor fuel system is compromised, but cannot find a schematic of the fuel system in order to start disassembly and inspection of components. PLEASE, ANY HELP or SUGGESTIONS WOULD BE GREATLY APPRECIATED!!

Sorry, I forgot to document, it is an Electronic Fuel Injection model.

 

[wn6ngp]

I don't know about your model but some of the fuel injected mercs in the 100hp range have more than 1 fuel pump. Chances are there is a filter(s) screen clogged up somewhere or clogged up in the pumps themselves. You are lucky it does anything if it sat up that long with ethanol fuel in it. You have to get rid of ALL that bad old gas. I had a problem like this and what I had to do was cut the fuel line and connect up a temporary fuel tank with fresh clean fuel until I could get rid of old gas in the tank. for the future can you get ethanol free? Its a motor saver.

 

[ErnieMac]

I don't know about your model but some of the fuel injected mercs in the 100hp range have more than 1 fuel pump. Chances are there is a filter(s) screen clogged up somewhere or clogged up in the pumps themselves. You are lucky it does anything if it sat up that long with ethanol fuel in it. You have to get rid of ALL that bad old gas. I had a problem like this and what I had to do was cut the fuel line and connect up a temporary fuel tank with fresh clean fuel until I could get rid of old gas in the tank. for the future can you get ethanol free? Its a motor saver.

Thanks for the advice. As I am new to boating, I know nothing about outboards, although I have been employed as an industrial mechanic / electrical & instrumentation mechanic, so do have trouble shooting skills, and logics. However what I don’t have is a schematic diagram of the fuel system for this motor. Any ideas out there where I can find one? Also in a perfect world I would be able to get my hands on some servicing documentation for the individual fuel system components. ANY HELP will be GREATLY appreciated, and not forgotten!
Thanks

 

[wn6ngp]

Thanks for the advice. As I am new to boating, I know nothing about outboards, although I have been employed as an industrial mechanic / electrical & instrumentation mechanic, so do have trouble shooting skills, and logics. However what I don’t have is a schematic diagram of the fuel system for this motor. Any ideas out there where I can find one? Also in a perfect world I would be able to get my hands on some servicing documentation for the individual fuel system components. ANY HELP will be GREATLY appreciated, and not forgotten!
Thanks

Given your experience you should be able to maintain this motor by yourself. What you need now is to buy a shop manual. Do some googling for merc shop manuals. Once you get that motor running the first thing you need to do is check the water pump and gear oil in the lower unit before you venture out. I assume you know not to run the motor unless it is in the water or on "ear muffs" to supply water.

I used to check this forum frequently and there were lots of experts on here. Not sure what has changed. Maybe they are on vacation. I hope that they have not left. Usually one of them would have requested your motor s/n by now. The details of these motors vary a lot even within year models so s/n can be important.

 

[ErnieMac]

Given your experience you should be able to maintain this motor by yourself. What you need now is to buy a shop manual. Do some googling for merc shop manuals. Once you get that motor running the first thing you need to do is check the water pump and gear oil in the lower unit before you venture out. I assume you know not to run the motor unless it is in the water or on "ear muffs" to supply water.

I used to check this forum frequently and there were lots of experts on here. Not sure what has changed. Maybe they are on vacation. I hope that they have not left. Usually one of them would have requested your motor s/n by now. The details of these motors vary a lot even within year models so s/n can be important.

Thanks so much for getting back to me. I sure could use some of the EXPERTS help!! My better half is really getting on me about this, and seeing as I have just retired and am now on a fixed income! I’d really like to tackle this myself if possible. The SN for this motor is “OT550615”. Any recommendations on where to get an OEM, or good jobber service manual? Thanks so much for your help to date. Looking forward to hearing more from you, and others!

 

[ErnieMac]

Given your experience you should be able to maintain this motor by yourself. What you need now is to buy a shop manual. Do some googling for merc shop manuals. Once you get that motor running the first thing you need to do is check the water pump and gear oil in the lower unit before you venture out. I assume you know not to run the motor unless it is in the water or on "ear muffs" to supply water.

I used to check this forum frequently and there were lots of experts on here. Not sure what has changed. Maybe they are on vacation. I hope that they have not left. Usually one of them would have requested your motor s/n by now. The details of these motors vary a lot even within year models so s/n can be important.

Sorry for missing this when i initially posted, it is a 4 STROKE!

 

[ErnieMac]

HELP!! 2002 60HP 4 Stroke Need FUEL SYSTEM HELP!!!
I could really use some help here. This motor sat for almost 3 years with ethanol gas in tank and lines (new to boating and didn’t know about running motor dry of fuel before laying up for long periods of time). Looks like I need to remove and clean all fuel component. I’m sure I can do this, but would really appreciate some schematics / tech doc on the fuel flow and specific components prior to disassembling. CAN ANYONE HELP ME PLEASE…..VERY DESPERATE AND HAVE JUST RETIRED, SO ON A FIXED INCOME!