At a Loss!?

[dickenscpa]

I'll try to be as thorough as possible so as to give you the best info I can, sorry if this is long.

I bought a 14' fiberglass tri-hull with a 1973 Mercury 402 40HP outboard. Had to keep priming the bulb to keep it running. It would get up and kinda go, but not what I'd call plane. Did a lot of research on this board and bought a manual and rebuilt the fuel pump, not much better. Cleaned and rebuilt the carb. It's a 2 cyl and only 1 carb.

About a week ago I was working on it and didn't button the cowling back up. Came home from office 7/3/07 was in a hurry to fish so I buttoned it up quick and forgot to put the boot back on the top plug. Ran like crap. Did a little maintenance on the water and put the plug wire back on. It feels like it's run on 25% power every since. I have to prime the bulb and put the warm up lever half way up now just to get it to start. Have to leave it there to put it in gear or it dies. Pumping the bulb doesn't help anymore.

Here's what I've done so far:
1)New fuel, fuel tank, fuel line/bulb
2)Rebuilt fuel pump
3)Rebuilt and cleaned carb (Wasn't that dirty)
4)Checked compression (Top cyl 132 bottom was 150)
5)Spark checked out fine (In driveway and under load)

I don't know what else to do? Compression, fuel and spark, what's left? With the warm up lever half way and full throttle, I might get up to 8mph if I paddle at the same time.LOL!

TIA for the help!

I also changed the oil in LU. Didn't look to be water in the LU and I drained it all and pumped new in.

 

[diaric]

Re: At a Loss!?

you've covered most of it. have you looked at the timing at all? then link and sync?

 

[dickenscpa]

Re: At a Loss!?

I told the guy at the auto parts store that I'd probably be back for a timing light, should have went ahead and bought it while I was there.

The link n sync, I have noticed that my warm up lever and my throttle have gotten loose. By loose I mean, my warm up lever goes about half way before I even feel the slightest bit of tension. Same with throttle, although not near as bad. Will a link n sync help this or is this just a tighten the cables type of thing?

BTW, really appreciate your input!

 

[diaric]

Re: At a Loss!?

link n sync will put you through the procedure to make sure your cables are set properly. the throttle cable should start to move just after the gear shift moves and engages gear in any direction. cables could be a little stretched or throttle plate in controller could be wearing a bit and getting sloppy. it would be wise to check that throttle cable is starting to move at this point and opening carb all the way when it reaches the end

 

[dickenscpa]

Re: At a Loss!?

Thank you. I'll start the link n sync procedure this afternoon and see if that helps. This will probably be my last stab at getting this thing running right. I bought the whole deal for $700 so it's not like I'm out much. My son just turned 5 a coupla weeks ago and LOVES fishing, I bought this for he and I to enjoy, but I can't take my son out in something I don't feel comfortable in. I've already had to be towed in 3 times since I bought it 3/31/07, luckily I was by myself.

 

[dickenscpa]

RE: Updated

RE: Updated

OK, apparently after going thru link n sync instructions, I recheck for spark because apparently I'm supposed to be getting 7/16" good blue spark. The bottom wil get a good 3/4" if I want and the top is getting nothing. I don't know if my eyes were playing tricks on me the other day or what. However, no spark on 1 of 2 cylinders would sure make sense considering the SIGNIFICANT power loss and the inability to stay running.

I think I've narrowed it down to a bad coil. I know this is elementary to most of you and I TRULY appreciate all the help so far. This is what I did to determine that the coil on cyl 1 was bad. Plug wire on bad coil was switched to good coil and I got spark, so I don't think I have a bad plug wire.

There is a green lead from each side of the switch box going to each coil. I took the green lead from the bad coil and put it on the good coil and got a good long blue spark. Took the green lead from the good coil and put it on the bad coil and still no spark there. I'm assuming that means the switch box is OK.

I have a good local NAPA store here. They had the kit for my carb rebuild in stock and when I ordered my fuel pump diphragm kit, it was at the store the next day. If it looks to you guys like my thinking was sound in determining the coil was bad, I could order it tomorrow and probably have it Thursday and be back on the water Saturday!

Again, thank you so much for all the help!

 

[BF]

Re: At a Loss!?

sure looks to me like you have it nailed. From your early description it sure sounded like it was only running on 1. With 2 cyl and only 1 carb, that makes ignition or loss of compression/air/water leak the most likely culprits. Good luck, and don't give up! You gotta keep that 5 y.o. fishin'... I've got 5/7/9 year olds so I know what a big deal a fish is to a little guy/gal.

 

[dickenscpa]

Re: At a Loss!?

sure looks to me like you have it nailed. From your early description it sure sounded like it was only running on 1. With 2 cyl and only 1 carb, that makes ignition or loss of compression/air/water leak the most likely culprits. Good luck, and don't give up! You gotta keep that 5 y.o. fishin'... I've got 5/7/9 year olds so I know what a big deal a fish is to a little guy/gal.

THank you. I feel better about ordering the part after hearing confirmation that I'm on the right track. The only problem I had out of this engine prior was having to prime the bulb to keep it going. It used to sound like a sewing machine. I wonder if taking off without the plug wire on that cylinder caused it to maybe arc and fry that coil? The coils aren't expensive, $20 or so, but not like I want to replace one every month or so either. I hope that's what caused it 'cause I can control that. Hope I don't have a bigger problem causing coils to fry.

BTW, my son was fiddling with his rod/reel casting with a weighted plug as I was working on the boat and said, "Daddy, can we please go fishing Saturday?" I'll take him bank fishing if nothing else.LOL!

 

[j_martin]

Re: At a Loss!?

Leaving the wire off the plug can burn out the coil, if it's a little weak to start with.

You might have found all your trouble with one lucky mistep.

John

 

[dickenscpa]

Re: At a Loss!?

Leaving the wire off the plug can burn out the coil, if it's a little weak to start with.

You might have found all your trouble with one lucky mistep.

John

Thanks for the input. I feel even better that my problem will be solved with the new coil now. I ordered it yesterday afternoon and it came in this morning. Pick it up on my way home tonight and install.

Between the carb job, rebuilt fuel pump, new coil (the other coil looked very new), LU oil change and new gaskets this thing ought to run like a top now. I was getting ready to sell this boat for a loss and start over. The switch box and wiring harness look to be very new. The switch box is definitely not OEM and the wiring harness is clean as a pin.

One last question. The 2" wire on the bad coil that goes from the neg stud to the coil cover, I'm assuming a ground, was an aluminum stranded wire. When I unscrewed it, it was so bad it fell into halves. I took a piece of 12 g solid copper and trimmed both ends and put eyelets on each end. Then I took shrink and a heat gun to it. That will handle it won't it?

Thanks Again!