Evinrude 235

[keysrat]

I have a 1982 Evinrude 235 that has a build up of gas in the bottom port cylinder. I have had the engine for one year and have had no problems until two months ago. At that time I discovered various fuel leaks. Three recirculating fuel hoses from behind the carb were spewing fuel and smoke and the top carb was leaking fuel. I went around and fixed all those problems.I capped the small hoses with screws and cleaned the carb. Went to start the engine and the starter would not push the flywheel but the starter will engage. Cleaned the connections went back to start same thing happened. The battery is new. I went around took the spark plugs out and when i took the bottom port one out a cup of gas poured out. Put all plugs back in and tried to start again. Same thing happened but the flywheel moved a little. The boat has an external holley fuel pump to feed this hungry beast. This fuel pump may have been left on at one point before I owned her. When I bought the boat the owner warned me not to keep the fuel pump on. this leads me to believe he might have left it on at one point. Any way the engine will not start. why am I getting so much fuel in that bottom cylender? Is some gasket or seal leaking? Is this some kind of carberator problem causing the excessive gas build up in only one cylinder? Does this have anything to do with the engine not starting and the flywheel not spinning? Thanks in advance for all your help. If you need more info just let me know and I will try to supply it!

 

[Dhadley]

Re: Evinrude 235

Welcome!!<br /><br />I would suggeat we get rid of the electric pump. For several reasons but aside from safety -- you dont need it.<br /><br />Now, are the stock fuel pumps still there?

 

[keysrat]

Re: Evinrude 235

The stock fuel pumps appear to have been removed all I see are the two fuel filters. The engine is run at moderate to high rpms if that makes any difference in regards to the electric fuel pump. The previous two owners had concern with detonation and cylinder temp. I always run 93 octane and I add a little extra oil to the 50:1 mixture. I believe the flywheel is the small 9amp. Do you suggest I replace the electric fuel pump with a stock one? Why besides safety? Thanks

 

[Silvertip]

Re: Evinrude 235

The engine was designed to run fine with the stock pump. There was no reason to add the electic. The problem with an electric fuel pump is that in the event of an accident or if you leave the key on, the pump will run constantly. If you have a fuel leak the pump will feed the resulting fire if something touches one off. Bad idea. One or more carb floats is not shutting off the fuel flow or else the pump has too much pressure and is overpressuring the needle and seat. Reinstall the orginal pump and rebuild the carbs. Pull the plugs, unhook the electric pump, disable the ignition and spin the engine over to expel excess fuel. The starter couldn't turn the engine because of hydraulic lock from excess fuel.

 

[Silvertip]

Re: Evinrude 235

The engine was designed to run fine with the stock pump. There was no reason to add the electic. The problem with an electric fuel pump is that in the event of an accident or if you leave the key on, the pump will run constantly. If you have a fuel leak the pump will feed the resulting fire if something touches one off. Bad idea. One or more carb floats is not shutting off the fuel flow or else the pump has too much pressure and is overpressuring the needle and seat. Reinstall the orginal pump and rebuild the carbs. Pull the plugs, unhook the electric pump, disable the ignition and spin the engine over to expel excess fuel. The starter couldn't turn the engine because of hydraulic lock from excess fuel.

 

[johnrude]

Re: Evinrude 235

Do away with the electric.

 

[Dhadley]

Re: Evinrude 235

What are the "two fuel filters" that youre seeing?<br /><br />What do you consider moderate to high rpms?<br /><br />Since youre running 93 octane the motor must be modified. What has been done?

 

[keysrat]

Re: Evinrude 235

Well, the electric pump is tossed. I did rebuild the top carb so i will rebuild the other two. I hope thats all it is! Thanks a bunch for the help!

 

[keysrat]

Re: Evinrude 235

The two fuel filters are next to the carbs on the port side of the cylinder the fuel line goes directly into the top filter. Top rpm that I run is 6200rpms and I average around 5000rpms. The only mods I am aware of are carbon fiber reeds, air box removed and exhaste relief. Thanks,

 

[Dhadley]

Re: Evinrude 235

I think what youre refering to are the stock fuel pumps. Each one should have 3 hoses. Fuel in, fuel out and a pulse line. <br /><br />I'd almost bet the lower one has a busted diaphram. That'll pump gas ringht into the #6 cylinder (lowest port cylinder). Happens sometimes with electric pumps forcing fuel in.<br /><br />6200 is nothing for that motor but a very good set up rpm. High test fuel isnt good for the motor if it is indeed stock. Make sure the heads havent been cut. Folks love to do that. If they have been cut you may be stuck with 93 octane.

 

[reeldutch]

Re: Evinrude 235

dhadley,<br /><br />why do you have to use higher octane with cut heads?<br /><br />just a question.<br /><br />reeldutch

 

[Dhadley]

Re: Evinrude 235

With tighter heads he may need the octane to keep the motor alive. Usually with cut heads the jetting has been changed too.

 

[keysrat]

Re: Evinrude 235

Dhadley,<br /><br /> How will I know if the diaphram is busted, is it pretty obvious? The only reason I run 93 is it was recommended to me by the previous owner. The heads may have well been cut, how do I check?<br />Thanks, Keysrat

 

[Dhadley]

Re: Evinrude 235

Take off the pulse line -- the hose closest to the block and going to a fitting on the block -- and pump the bulb. If its busted the gas will come out that hose.<br /><br />The previous owner should be able to tell you why he ran high test fuel. Otherwise youd have to measure the heads. Either cc them or measure the depth compared to an uncut head of the same casting number.

 

[keysrat]

Re: Evinrude 235

The diaphragm appears to be fine. I took off the pulse line and no gas came out when I pumped the bulb. I also took apart the fuel pump and the diaphragm had no visible rips or holes. The previous owner unfortunately did not have to much info on the engine. He just relayed to me what he "remembered." The heads probably are cut if he recommended to use 93. Hopefully I will have some time tomorrow to take the carbs off. Should I also check the top fuel pump?<br />Thanks again,<br />I will post the results when I have them.

 

[Dhadley]

Re: Evinrude 235

It wouldnt hurt to check the other pump but if no fuel was getting into #4 like it was in #6 then its probably OK. If the pump was OK then the extra fuel has to be coming in thru the bottom carb. I think youre headed in the right direction by cleaning all 3 carbs.<br /><br />Good luck! Keep us posted!

 

[keysrat]

Re: Evinrude 235

I cleaned the carbs and expelled the fuel from the #6 cylinder. Tried to start and the problem happened again, the #6 filled with fuel. No fuel is comeing from the front of the carbs so I guess the carbs are ok. Is there any other problem I should look for in the bottom fuel pump besides the diaphragm. The fuel must be getting into the cylinder from the fuel pump if it is not the carbs correct? Is there check valves or something else in the fuel pump that could cause the fuel to dump into the cylinder?<br />Thanks, Keysrat

 

[Dhadley]

Re: Evinrude 235

Well....lets see. Are you sure the hoses are hooked up correctly? The fitting on the cap is fuel out. The next fitting on the bottom of the pump is fuel in. The fitting closest to the back of the pump is the pulse line which should never have fuel. <br /><br />Since you dont need the pulse line to start the motor, you might disconnect them and plug them on the block side and try to start the motor. Or switch the pumps.

 

[keysrat]

Re: Evinrude 235

I just rechecked to see if the pulse line has fuel in it when I pump the bulb and there is a trickel of fuel coming out. I am going to get a fuel pump kit and go through it. From what I understand it must be that fuel pump. The hoses seem to be hooked up correctly.<br />Thanks for all the help and when I get this pump fixed I will post the hopefully positive results.

 

[Dhadley]

Re: Evinrude 235

Sounds like you have it under control.