Evinrude 140 needs lots of TLC

proaudioguy

Petty Officer 2nd Class
Joined
Aug 12, 2010
Messages
171
Re: Evinrude 140 needs lots of TLC

I believe it's a 13.75". It came off my '89 140 so it should slide right on yours. If we could coordinate on a nice weekend we could hook up on the St. Johns and do some prop testing. They are very easy to change out. You could try out my 23 pitch too if the 19 still seems too low. When you get your wiring sorted and ready to run, give me a shout and we can set something up. My email is overkill82k5 at yahoo dot com. I get it directly to my phone so it's almost instant.

Jamie

That sounds like a blast!
 

proaudioguy

Petty Officer 2nd Class
Joined
Aug 12, 2010
Messages
171
Re: Evinrude 140 needs lots of TLC

Got the new controls!!! Now I just need to figure out which wires to order. Any help appreciated. I don't mind taking it off the forum.

Here is what I WANT.

New controls. Check
New Control Harness from Controls to Engine (big red plug on engine)
System Check upgrade kit with new oil sender and the system check wires in the harness.

Is my best bet to buy a newer control cable (part number please) and then a SHORT adapter to the big red plug on the engine (part number please)? The red plug engine harness is brand new BTW. Would said adapter have the wires for the system check set up broken out next to the big red plug?

Also how does the POWER TRIM control fit in with all this?

I'd like to have this stuff ordered in the next few days. I have a limited amount of down time and want to get this part of the re-wire job done. Any help is greatly appreciated.
 

nymack66

Petty Officer 1st Class
Joined
Aug 5, 2009
Messages
356
Re: Evinrude 140 needs lots of TLC

Go to this link, you will need to call them CDI makes the engine side harness not sure about the remote side since I don't know your part number. I purchase my engine harness from them and the my remote and the rest of the cables on from ebay all brand new and very cheap.

http://www.marineengine.com/parts/c...engine.com/parts/cdi_electronics/cdi00005.htm

Ebay search on "omc harness" turned up this ? pls verify before u buy ...
http://cgi.ebay.com/ebaymotors/New-...8188380QQptZBoatQ5fPartsQ5fAccessoriesQ5fGear
 

jonesg

Admiral
Joined
Feb 22, 2008
Messages
7,198
Re: Evinrude 140 needs lots of TLC

I ordered the carb kits. I couldn't find them on this site so I got them from a google search. I also ordered the missing Part number 0432639 Roller Cam Follower (#30 in the parts breakdown). I had noticed the absence of that part (it was mostly missing) caused a really bad idle, but sliding the left over piece in contact with the parts it is supposed to act as a shim between helped a lot. I used some ZIP ties as a spacer to replace the part temporarily. I can't believe they want $7. for what is basically a sacrificial piece of plastic tubing less than an inch long.

Is there anything else I need to rebuild the 4 carbs besides the carb kits, and some solvent and carb cleaner? I do not have a torque tool that works in inch pounds, so I'm open to suggestions as to what to buy for that.

You have a lathe for making those types of parts, I made mine from delrin, fits nice.

Get the factory service book, its light years better than the two you have.
www.outboardbooks.com

Rebuild carbs one at a time so you don't get lost, be carefull to identify jets.
Run single strand copper wire through orifices and jets.
Its very simple.
http://www.youtube.com/user/TheMarineDoctor#p/u/9/o5cxBMDezuU
 

jonesg

Admiral
Joined
Feb 22, 2008
Messages
7,198
Re: Evinrude 140 needs lots of TLC

Craigslist for used alum tanks, $150 or less.
Or look at some of these used tanks..
http://www.massmarineparts.com/fueltanks.aspx

Ebay for shifter controls and cable/ harnesses etc.

Personally I would cut the deck off and re-do the whole fuel system, fill hose too.
 

proaudioguy

Petty Officer 2nd Class
Joined
Aug 12, 2010
Messages
171
Re: Evinrude 140 needs lots of TLC

Craigslist for used alum tanks, $150 or less.
Or look at some of these used tanks..
http://www.massmarineparts.com/fueltanks.aspx

Ebay for shifter controls and cable/ harnesses etc.

Personally I would cut the deck off and re-do the whole fuel system, fill hose too.

Yea, I've already had the tank out. It was just so huge, it was very hard to clean, but I got most of it out at that time. Just not enough!
The fill hose is not bad, but I did replace the fuel line while I was in there just to be safe. The fill tube is only about 3ft long.
 

proaudioguy

Petty Officer 2nd Class
Joined
Aug 12, 2010
Messages
171
Re: Evinrude 140 needs lots of TLC

I am now the proud owner of new controls I picked up a few weeks ago, the system check upgrade kit came in today, as well as the system check Tach I picked up a while back. I got a slamming deal on the system check upgrade kit from just constant part number searches until I found someone listing NOS parts they wanted to ditch. It is missing the horn and the ZIP ties (hose clamps) which I found odd. Perhaps it was misplaced when the parts were originally ordered. With the horn missing it may not be as good a deal as I thought, but the controls came with the horn anyway so it still works out OK and it is nice not to have paid $55 more then try to sell a horn for $30. This kit has a new oil cap (not sure why), a new oil pick up with sensor, and oil hose. It has 1 harness cable that connects the NEW controls to the red plug engine harness. It has a second harness cable for the system check side of things.
Borrowing this picture from another site because it's much larger than the BRP pic. This is not where I purchased the kit.
http://www.boats.net/images/diagrams/omc/IMAGES/176729/15A.png

The installation instructions for the wiring were also missing although the instructions for the oil tank retro was there.

I "think" I can figure out the wiring except for one thing. The harness comes with a 3 socket connector. The controls also come with a mating 3 pin connector. The controls do not have the pinned wires installed in the connector. The wire colors are NOT the same. I don't know which wire on the control side goes to which wire on the harness side.

Harness colors are green with white stripe, blue with white strip, and white with brown or tan stripe.

Control colors are Green, Blue, Red. I suspect this is related to the TRIM controls but I'm not certain.

The colors of the 6 pin plug don't match up either but those plugs are assembled so I must assume they are wired correctly. ;o/

If anyone has the wiring schematics for the system check engines AND the old 1990, or has the answer, it's most appreciated.
 

proaudioguy

Petty Officer 2nd Class
Joined
Aug 12, 2010
Messages
171
Re: Evinrude 140 needs lots of TLC

The big red plugs are gay as it turns out. Not sure if this is a manufacturing mistake or what. Going to email BRP to find out.

Update: FYI BRP has no tech email address. You have to call them which I am not going to do. I seriously doubt they want to spend hours on the phone with me while I learn. OTOH a few emails and some attached docs and I'd be good to go. A very nice ebay buyer is going to scan the instructions for the conversion kit.
 

proaudioguy

Petty Officer 2nd Class
Joined
Aug 12, 2010
Messages
171
Re: Evinrude 140 needs lots of TLC

I haven't heard anything back yet but it looks to me that the big red plug is correct and that this cable is actually a very long (10ft) adapter cable that adapts a NEW engine to an old boat, and adds system check at the same time. A more appropriate kit would be one that has a female big red plug on one end, as well as all the system check related wires and plugs, an additional aux harness to connect to the sensors on the engine, and the oil sender. Looks like I'll have to cut this adapter cable up and use the connectors. Does anyone know a source for a new female big red connector? I just need about 1ft of wire which I would splice into this new harness cable.
 

tony edwards

Cadet
Joined
Dec 4, 2010
Messages
16
Re: Evinrude 140 needs lots of TLC

sounds to me after reading all of your book, it would have been better to take it to a certified tech. but anyway, the factory jets are right for your area unless it came from somewhere that is extremely high altitudes. i think you should replace the jets with what came in the engine. the primer, the thing with the red lever, the lever should be turned back to where the lever is on top of the solenoid. there is a chance that the pin made of plastic) under the cap with 4 screws holding it on to the primer solenoid could be broke. you will have to remove the cap to see. there is no torque specs for the screws. just tighten gently primer bulb will not be tight after running. it shouldnt take more than a squeeze or two to bring it back to firm. engine not running, but recently ran. the gauges you need in your boat are: tach. fuel, volts, water pressure. and fuel. any others are to make you feel warm and fuzzy. the linkage and synchronization is critical on any two stroke. most manuals will walk you thru this. if fuel and timing are not correct, it wont run correctly. calm down and back up. possibly all you needed in the beginning is a good carb cleaning. also, all the chemicals in the world wont clean the fuel system out completely. the purple wire is from an updated vro pump. they added the purple wire for 12 volts. it can be tied into any purple wire on the engne. u did the right thing changing the plug to the 4 wire one. ok. i will get off my soap box now. been in this business over 38 years and havent found a 140 i cant fix. i believe you have a loop charged engine which is a power house. u will be impress when you get it goin.
 

proaudioguy

Petty Officer 2nd Class
Joined
Aug 12, 2010
Messages
171
Re: Evinrude 140 needs lots of TLC

Oh I've been running the hell out of this boat since last August. The carb kits did the trick there, but the gas was still full of crud. Didn't have it running really well until mid September when I added the pre filters. The fuel dirt issue has been alleviated by removing the pick up screen and placing an old school inline filter BEFORE the water separating filter (actually 2 in parallel). That little pre-filter is doing a great job of collecting the particles that occasionally get sucked up and we haven't had the engine starve for fuel since. I suppose I could just let the big filter do it but then I'd be changing that a lot more often and they are EXPENSIVE.

I currently am in the process of converting to system check, installing the new gauges and installing the new controls. I have a piece of starboard and 2 of the 4 or 5 gauges I will end up with.

I wasn't going to get a water temp gauge, but if that is good to have, I will pull the trigger. Since the gauges are NOS, I would like to get advice on how to install them, particularly the water temp. Is there a sensor for that or does it use the sensors that are currently on each head?

The tach has system check, I have that wiring worked out.
The Volt gauge wiring is pretty self explanatory. (I have 3 batteries and was considering getting 3 gauges or 1 gauge with a 3 way selector switch. The gauges are in my shopping cart, just need to pull the trigger) Thoughts?
Fuel gauge is easy.
Trim gauge is another questionable one. I like the idea of being able to get repeatable results. My dad says I don't need it.
Hour meter is probably pretty useless at this point. I'd like to eventually re-power with an ETEC 225HO in which case an analog hour meter may be obsolete anyway.

I also have the new oil pick up tube and sensor for system check.

It would help immensely if someone could tell me the pin out for this harness. Even a scribble would be great.
http://i213.photobucket.com/albums/cc281/originalseahorse/WirningHarnessMWS.jpg

I'll admit I have spent only a little less money over all, but the work I've done is top notch and I have learned a ton about outboards and boats in general. I am not the least bit intimidated about working on this engine now. When I started this last July, the boat had sat for 3 years waiting for me to change the impeller (as I was told by my mom to do before using it) because I had no clue how to work on a boat engine. I was comfortable with small block V8s pre-computer engine management and complex emission controls. I didn't even comprehend how a 2 stroke worked. Now I feel comfortable rebuilding one.

Once I have all this wiring done, I'll start fixing the trailer issues. Once that's done, I am going to get the cosmetic issues dealt with. My wife just wants a new boat, but this is a great boat and I'd rather put $10k into it than spend $10k on someone else' problems which I'll still have to fix. Did I mention I got the boat for free? When all is said and done and I am financially able, I'll end up with a 23 or 24ft CC and simply give this one to my son. I just don't know if the oldest will get it or the youngest will get it. One of them may already have a nicer boat by the time I'm done with it!

Now I have a cable I don't need due to purchasing the wrong adapter.
http://www.tigeraudioinc.com/systemcheck/omc0176383.html

Part of my cosmetic plan is to have a set back bracket with dive platform installed, have all the old holes filled where different previous owners have drilled, have the bottom paint removed, and have the entire thing gel coated. I may have the bumper replaced at that time just to make it all look new (wife will like that). I'd also like to close in the transom, but have a water tight door back there. I also want a custom back seat that swings clear of the transom. I have considered several complicated designs, but am open to ideas. This is to allow easy access to the dive platform, but it will also help my dad get in and out of the boat. He's got serious mobility issues these days. My current wiring project includes enough length for the set back bracket. I plan to later add a kicker motor and I'm welcome to suggestions there. This would be for long distance no wake zones which we have a lot around here, exploring the back country areas where the big engine tends to hit the bottom, and for security when in open sea. We'd really like to go to the Bahamas during a calm weekend but I would be leery of making that short trip without an AUX engine and an enclosed transom.

Thanks for reading my book. I'm hoping someone will benefit from the thread. Had I read all this when I started I would have done things differently.
 

R1racer

Petty Officer 3rd Class
Joined
Jul 7, 2009
Messages
83
Re: Evinrude 140 needs lots of TLC

These ....> particles that occasionally get sucked up <....... Are simply your sending unit float the ABS black foam are breaking a part or being disintegrated... Have you pulled the sending unit out and inspected this little part ...Ethanol break it down and no place to go but the tank ..

I had this happen to one of my tanks as I got 2 tanks ,it was as simple as removing this bad sending unit ABS foam float and replace it ... This is just suggestion
 

proaudioguy

Petty Officer 2nd Class
Joined
Aug 12, 2010
Messages
171
Re: Evinrude 140 needs lots of TLC

These ....> particles that occasionally get sucked up <....... Are simply your sending unit float the ABS black foam are breaking a part or being disintegrated... Have you pulled the sending unit out and inspected this little part ...Ethanol break it down and no place to go but the tank ..

I had this happen to one of my tanks as I got 2 tanks ,it was as simple as removing this bad sending unit ABS foam float and replace it ... This is just suggestion

Thank you. The cork float was replaced with a brand new (supposedly ethanol safe) plastic sending unit end of July. Since then I use ethanol free fuel. The cork float was indeed in bad shape. The gas tank was very well washed out since that sending unit was replaced. These particals might be varnish becoming loose, I don't know. I imagine they will eventually be flushed out with use.
 

proaudioguy

Petty Officer 2nd Class
Joined
Aug 12, 2010
Messages
171
Re: Evinrude 140 needs lots of TLC

Here is the new dash panel so far. It will also have 2 cigarette lighter power ports for phone chargers and such. There are 2 more panels with switches and an iPod dock but I'm short a few parts. Still need to wire it all up. I thought today would be a good day to work on the boat but it is gloomy and looks like rain. I think I'll go find some switches and order some tinned wire and amphenol terminals.
 

Attachments

  • dash.jpg
    dash.jpg
    66.5 KB · Views: 0

proaudioguy

Petty Officer 2nd Class
Joined
Aug 12, 2010
Messages
171
Re: Evinrude 140 needs lots of TLC

Ran the new control cable with system check included. Wired in the new trim plug, the System check plug, and the other 6 pin plug to the engine harness. (now I'm etec ready) Also installed the new dash panels. The controls are going to be a bit harder as it looks like I'll have to adjust the linkage a bit once that's done and I gave up today when I couldn't find the C clips and the mounting screws. That's the downside to collecting parts over several months. Also in the process of running long battery cables up front where the aux battery will be installed. I picked up a second battery switch as well. I was told even if I needed to use it to crank, 4-6 gauge would be fine for a 20ft run (40 ft round trip worst case). I am using 2 gauge SAE (told by the surplus place it came from Boston Whaler). I'd prefer #2 AWG but this is what I have. Also in the process of rewiring (correctly) the bilge pump with a new float switch. The old switch was fine but the wire was corroded. I also picked up an Aux bilge pump. It's a Rule 1500, which turns out to be rated much less when you run 3ft of hose. I think the main is 800gph. Do you guys think that's large enough for a 20ft DC with an outboard? Should I move the 1500 to main and pick up a larger unit for the aux? The aux will be wired to a switch in the dash and has no float. The aux uses the float and has a switch in the dash as well. The next time I forget to put the plugs in I'll just hit both of them!
 

nymack66

Petty Officer 1st Class
Joined
Aug 5, 2009
Messages
356
Re: Evinrude 140 needs lots of TLC

Seriously any bilge pump under 1500 is a joke when you take on water ...
 

proaudioguy

Petty Officer 2nd Class
Joined
Aug 12, 2010
Messages
171
Re: Evinrude 140 needs lots of TLC

Good point but what is the right size? These things are really expensive. My dad thought the old one he had in there was a 500. When I purchased the new one at Walmart, the largest they had was 800. He figured that was fine and overkill. I was certain the old one was 1500 and turned out to be right. I was always planning to get a larger one. He still thought the 800 was plenty. He has a ton more experience than I, including having owned a 37ft (and living on it) for several years. Before that a 34, and The under 30 footers I lost count of years ago.

So the way it stands now I have the 800 as the main with the float switch and the 1500 as the aux. I suppose I'll move the 1500 to main and get a larger one for the Aux pump but what size? It's only a 20ft boat. There is going to be a point where it won't matter if I had a 25,000 GPH pump it wouldn't keep the boat from filling up. In fact I'm of the opinion that if the Transom notch goes under, it's all over. Fortunately it floats very well and it's self bailing. Hopefully all the flotation foam is dry! HA HA.

On another note, I am nearly finished re-wiring. I decided to hook up the 3 batteries like this. The idea is to have the deep cycle for running the air pump (tubes), radio, phone and ipod chargers, lights, etc, while docked or at anchor. I had originally planned for the change over to be automated with a relay, because my family would not have to think too much. They will just have to remember to switch over. The upside, with a spare start battery, even if they kill the primary, they still have a chance of getting started.
Planning to add this http://www.northerntool.com/shop/to...erformics&cm_pla=Performics&cm_ite=Performics so I can hook up my charger with ease. Rotating the battery switches to the correct position will facilitate charging. I have 800 and 650 CCA batteries. Is it OK to charge them simultaneously? I would normally only charge them at the same time if they were exactly the same but I'll admit that idea is based on speculation. It would obviously be better for me to be able to charge them at the same time. The deep cycle would need to be charge separately I imagine since there are deep cycle settings on the charger.

Edit,....got it all wired up Friday and it all worked as expected except the anchor lamp. It was getting cold again and was dusk so I didn't get a chance to suss it out. The socket is pretty corroded so maybe that's it, but it worked before. Seems unlikely it would be polarity related being a simple bulb. The nav lights came right up though.
The dash lights were interesting. The NOS gauges were lit but opaque, while the two newer gauges of the same style were back lit. They looked fantastic but didn't match the other gauges which kind of bugs me. Not that big a deal I guess but something to look out for.
 

Attachments

  • schem1.jpg
    schem1.jpg
    73.7 KB · Views: 0

proaudioguy

Petty Officer 2nd Class
Joined
Aug 12, 2010
Messages
171
Re: Evinrude 140 needs lots of TLC

Quick update. Had no further issues with the fuel. Got the tach working by replacing the regulator. A retired omc dealer at Silver Glenn told me that was probably the issue with the tach not working. My rpms max out at 5100. He suggested my prop was too big 15x17 and suggested I get the correct 13.25x17 to try, and a jack plate to work out the height.
 

levi_tsk

Ensign
Joined
Dec 26, 2010
Messages
907
Re: Evinrude 140 needs lots of TLC

that prop sounds about right man glad to hear you got it going and thanks for posting your solutions
 

proaudioguy

Petty Officer 2nd Class
Joined
Aug 12, 2010
Messages
171
Re: Evinrude 140 needs lots of TLC

Hoping to try out a prop or two in the coming weeks. Open to suggestions on places to get trial props from. I live near Daytona Beach. I'd just as soon go to a mom and pop shop locally than one of the online places. Seems like a good prop shop would be able to dial the prop in a bit once we figured out the best way to go. My number one goal is good fuel economy with no lugging, IE running the engine at the right RPM. My number 2 goal is a good hole shot. Number 3 is a good top speed. If I can't have them all then I'll take the number 1 and either of the other two. I do have a very good SST prop if anyone wants to make a trade.
 
Top