Carb removal from '82 9.9hp

[mountainsailor]

I bought the carb rebuild kit and the Seloc manual but there appears to be much more involved in removal of the carb than the manual indicates. They say disconnect choke, gas line, linkage, etc, then remove 2 nuts... and bingo. You can see one nut, but there is a ton of stuff in the way of the other... like an air filter (I think), the recoil starter, and a white nylon part that is part of the throttle linkage. I am more than a little hesitant removing these parts w/o a little guidance and assurance that these parts need to come off and how to safely remove them and re-install them. They don't seem to even appear in the photos in the Seloc manual.

 

[R.Johnson]

Re: Carb removal from '82 9.9hp

For me, just the easy way to gain room is to remove the flywheel, then the air box, and choke lever. Then remove the rewind starter screws, pulling it only part way up as not to disingage the starter spring, and push it aside. You can now reach the carb. nuts. Remove low speed needle valve to slide carb. out. Seems' like alot of work just to get at that carb screw.

 

[mountainsailor]

Re: Carb removal from '82 9.9hp

The flywheel, too, for sure? Will I need some specialized puller to do that?

 

[ottertail]

Re: Carb removal from '82 9.9hp

Take out the 4 screws that hold the air box cover on. remove the 2 screws and washers that hold the air box body to the carb and remove the air box.
remove the choke and choke guide plate. loosen the 1 bolt holding the rewind down but dont pull it out. gently lift the recoil assy complete with the bolt still in it, then push the bolt all the way back in, if you are careful you can lay t to the side and it will stall comlete, it would be better if ou spun a nut onto the bolt to hold it together, then you can pull cord out and get it out of your way. Now you have acess to the 2nd nut. The cam follower, ( the white nylon piece can be removed if you wish but not necassary) there will be a small spring that you have to unhook for the starter interlock. If you take your time and look it over good before you start and watch as you take it apart you will have no problem.

 

[PW2]

Re: Carb removal from '82 9.9hp

It's a 3/8" coarse thread nut that will hold the bolt inplace with the starter.

If you don't have one, get one before you start. I have no idea why anyone would take the flywheel off, unless they needed to for some other reason, unrelated to servicing the carb.

 

[mikesea]

Re: Carb removal from '82 9.9hp

Yep,the advice given,except for (with respect)the flywheel.I want to give a bit more importance to the recoil removal.You MUST be careful.Its spring loaded and can fly apart.As mentioned,remove the center mounting bolt while holding the unit togethe like a sandwhich,the 3/8 nut is a must,I use a wing nut,the larger marine battery wingbolt fits.Its not as hard as the book makes it seem.The starter recoil is the only bear of he job.Patience helps.

 

[R.Johnson]

Re: Carb removal from '82 9.9hp

Taking the time to remove the flywheel will save you a lot of grief with that starter. I'll take the flywheel off, you put the starter back together, we'll see who is done first.

 

[ottertail]

Re: Carb removal from '82 9.9hp

I will take that challenge! But then I have done countless of these over the past 26 yrs. Everyone has to find what works for them. Not every one does it the same way.

 

[R.Johnson]

Re: Carb removal from '82 9.9hp

In 26 years, have you ever been in a room full of starter spring?

 

[mountainsailor]

Re: Carb removal from '82 9.9hp

I see I opened up a debate here regarding the pulling of the flywheel. But, I'm not sure I got an answer to the flywheel puller question... as in, is there a specialized tool involved? Since I've never tried either method here I'm looking for the simplest (no special tools) and safest (least likely to screw something up that is hard to fix). Thanks again.

 

[R.Johnson]

Re: Carb removal from '82 9.9hp

If you don't have a flywheel puller, you can certainly remove the starter without it. I just do it that way because for me, it makes it easier to put the starter back on. When you take the starter off, you will find it has a tab on the bottom that goes into a recess in the block. Make sure you get the tab back in it's recess. If you pull the starter bolt out to far, there is a washer, or spacer between the starter pully, and the starter housing, don't let that slip out of place. I've been repairing outboards since the early 60's, so I have some rewind starter experiece.

 

[ratracer]

Re: Carb removal from '82 9.9hp

When I rebuilt the carb on my '88 9.9 2 years ago I used the carb removal procedure described and illustrated in the Johnson service manual. The procedure ottertail outlined is pretty close to the recommended procedure which does not require removal of the flywheel.

One thing that the manual recommends and which I found useful was to get a 3/8 -16 nut and keep it handy for when you loosen and remove the starter assembly. It's a bit tricky to do but you use 1 hand to keep pressure on the starter so the spring doesn't slip loose and use the other to thread and hand-tighten the 3/8 nut onto the starter mounting screw. Maybe I'm wrong but I doubt the setup would be that much different for your '82 than on mine.

I find the Seloc manuals sometimes useful, but the OMC/Johnson service manual much more so, you might consider looking into getting the correct one for your '82.

 

[mountainsailor]

Re: Carb removal from '82 9.9hp

Carb off w/o mishap, thank you for everyone's help, especially the 3/8" nut trick. Any tips for the re-build, or things to look for, or look out for? Again, I only have the Seloc manual and this will be my 1st card re-build.

 

[mikesea]

Re: Carb removal from '82 9.9hp

take it apart totally,as far as you possibly can,there were some different configurations of carbs for the 9.9 I cant remember what yours looks like.Pay attention to any gaskets ,where they came from,remove needle valve,1st cose it and count how mny turns it took to close,that will be your initial setting at re install,but not to worry if you forget,we start at 11/2 turns out.Depending what you see when you take apart.If parts look like junk.Order a kit off THIS website(your labor is free and instruction are free)be careful with the roller,they get brittle and break,you really want to soak the carb in a solution to break down any varnish buidlup etc.But I think the stuff is about 25 a gallon.I have used omc engine tuner and kinda brushed it on,leaving it puddle in tuff places.You might be able to get something like it at a NAPA auto parts etc.Whatever you get ,let it soak for a few hrs.I then use hot soapy water for an initial wash,compressed air is an asset to blow through the passages,but a can of carb.spray with the red extension tube works ok,DONT use the spray carb cleaner for the big cleaning,its not strong enough.Once all parts are good and cleaned,you also want to open the cap on the fuel pump,its where the fuel enters the system,there is a screen in it,remove if you can and clean screen,or at least squeeze clean fuel throug it,then put back cap and squeeze clean fuel through the supply to the car.Re install cab.Let us know how you do,

 

[mountainsailor]

Re: Carb removal from '82 9.9hp







Did this work? Can you see the pics? (The Seloc manual is of little help... I thought it was the only one available. I would have purchased an Evinrude manual if it was available.)There are some parts I wasn't quite sure of... like the 3 different size cap-like parts. There 2 places on the carb that look like possibilities for those "caps" but I'm not sure how to get off the existing ones. The carb looks very clean inside, unfortunately, was hoping it was a mess so would be more hopeful that this whole thing would work.

 

[mikesea]

Re: Carb removal from '82 9.9hp

If you look at your carb,you will see those caps,perhaps not all,but,they are welch plugs that when pried out give access to passages in the carb that otherwise cant be seen,I hardly removed them,unless the carb is full of dirt and crap that solution cant disolve,you would put them in the opening and tap them on the rounded side,that then causes the plug to expand into the alum casting,do you need to bother,my guess is nften carb kits come with lots of extra parts,like the extra gasket ,the larger gasket would be for a 15.Just use what you see and when finished discard the rest,it allows the manufacturer to just have 1 part # for more than 1 application

 

[mountainsailor]

Re: Carb removal from '82 9.9hp

Given that it's sunday, I don't have access to any soak-type carb cleaner. Like I said earlier, the carb is very clean... not a hint of varnish, sludge, sediment... nothing. Everything is bright silver colored on the inside and out. Using spray-type cleaner I hit everything twice and let it run into a pan... and the solution rinsed off clear. Should I still soak it? I suppose all it takes is one little piece of crud to foul the thing up.

I'm beginning to wonder if I'm barking up the wrong tree w/ respect to why the thing ran so horribly or not at all at times... but I'll press on and follow your recomndations.

 

[mikesea]

Re: Carb removal from '82 9.9hp

You could be right about the tree.What are the symptoms.?Those engines are pretty bullit proof,except for carbs when laid up,sometimes the fuel pump diaphrams go and can pour fuel into the engine through the small hole behind the pump that gets its pulse from.Or another biggie.The stop buttons go and the eng.can get intermittent or no spark,after yo decide on the carb,and put it on,if the problem is still there.Disconnect the kill button.You should have started by doing a spark and compression test.But ,we are here now.Get back.Gotta know the result.Mike

 

[mountainsailor]

Re: Carb removal from '82 9.9hp

Basically rough running, stalling, hard to restart, or not starting at all. Sometimes monkeying w/ the choke could keep it from stalling. I do know that it probably received very little winterization-type maintenance in the past... just out of the water, into the garage. And as far as I know it's always been in fresh water for very short seasons. How do I check on the fuel pump? Good idea to check now given the carb being pulled?

 

[mountainsailor]

Re: Carb removal from '82 9.9hp

well..the whole thing is back together. I did try to check the fuel pump function... , but as soon as we plugged the fuel hose from the tank, fuel went right through the pump & shot out the hose that would normally be connected to the carb... is this right? Shouldn't fuel only flow when the engine is being turned over and the pump is mounted? but no leak through the back vacuum hole. Anyway, we started it and... same as last year, runs roughly in idle, stalls evenually, and won't restart for some time... same scenario again. Any further ideas?