'92 40HP outboard starting issues

mthompson220

Cadet
Joined
Mar 31, 2012
Messages
12
I have a '92 40hp 2stroke outboard motor that I am having trouble getting to start relialby. I figured that it was a gas issue since I just had the switch box replaced and the carbs rebuilt a week ago, so I know that the ignition system is working.
Regardless, I noticed gas dripping at the fuel line connection port on the motor. So I rebuilt the fuel line and put a fresh bulb and filter in thinking that it was losing draw from the tank preventing it from getting gas. Once I did that it fired right away.
Nevertheless, I took it out yesterday, with totally different results:mad:. I primed the bulb, choked it and... nothing. Crank, crank, crank but no fire. Kept doing that, for a few minutes untill I was certain that it was well beyond flooded. Needless to say that it would occasionally stumble like it wanted to start but it refused until I was just about ready to pack up and go home (about 35 min). One last crank and it fired. We then drove it around to get it good and warmed up with no issue.:confused:
Once we got to where we were going to fish we stopped and shut it down. After about an hour or so we decided to move. Same thing, crank, crank, crank but no fire. So I just held down the ignition and played with the throttle and finally it started. It kept doing this all night, however not as bad as the first time.
I really don't want to have to keep doing this because I'm afraid that I'm going to burn up the starter. I can't seem to figure it out. I prime the bulb until it is stiff, but it doesn't always stay stiff when you pump it. And if I keep pumping it, the lower carb starts dripping gas and floods.

Like I said the bulb is new and the line is solid, no leaks or anything. I cannot figure it out. If you have any advice, please let me know, because I really don't want to have to replace the starter if this keeps going the way that it is going. Not to mention that it is extremely irritating.
 

crossroads123

Seaman Apprentice
Joined
Feb 26, 2012
Messages
47
Re: '92 40HP outboard starting issues

I too have a 40 hp with very similar starting issues. I have also replaced my bulb and the spark plugs it seems to start alright the first time, but after that it's crank, crank, crank. If I use the push to choke it still is hard to start and will die after it starts. If I can keep it running long enough to advance the thottle for 15-20 seconds it will idle and run fine when I put it in gear. I too worry about overheating and burning out the starter. I just bought the boat so I don't know the history, but the carbs both are clean on the outside and I have ran seafoam through the carbs.
Sorry I couldn't be of much help, but perhaps someone has the answer for both of us. Just know you are not alone.
 

SierraMark

Petty Officer 2nd Class
Joined
Feb 27, 2012
Messages
135
Re: '92 40HP outboard starting issues

I have a 1991 Mercury 40HP that just started doing the same thing this past weekend.

I was thinking of rebuilding the carbs to see if it fixed the problem but I am not sure it will help.

-Mark
 

mthompson220

Cadet
Joined
Mar 31, 2012
Messages
12
Re: '92 40HP outboard starting issues

I found out that the problem I was having was the electric choke. It was not activating properly at the ignition switch. Now all I have to do is prime it and play with the throttle and she fires right up. Hope this helps. Easy cheap fix, just the way I like it.
 
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