Mercury 25Hp Linkage adjustment/bogging after a long run

[brttc]

Hello, I have a list of problems that I can not get sorted on my motor. I've searched and cannot find an answer. Please see below:

Engine S/N: 0D215157
Linkage: Remote Cables

1: Motor runs great for several minutes, then I run back to idle (2 min), when I run back up to throttle, it will bog down. It does not fully die usually, just half the power and continues to vary in throttle. This has happened numerous tames and I can't figure out the issue. Oddly I can run forever but when I bring it back to idle, then back to power, the problems begin.....

2: My shift linkage is completely out of whack. Please note, it shifts just fine through forward and reverse, just looks incorrect. I will post a few pictures to help identify. My Idle Stop Screw doesnt hit the mechanical stop at any point through the linkage movement. The "cam" up front (I can't identify the part) is never either all the way back or all the way forward. I can't find any information on how to properly set full throttle/idle. Bottom line: Should I adjust the linkage so the cam is all the way forward/backward at full throttle?

What I've done:

Rebuilt carb with all new parts
Replaced fuel tank (brand new, filled with 92 grade ethanol free/seafoam)
Replaced all fuel lines/filter through the system
Spark plugs replaced with proper gap
Adjusted Idle Needle (I think I have it leaned right, please see plugs)

Thanks all for the help, I've spent many hours on the water trouble shooting this and can't get it dialed in.....

 

[flyingscott]

Your link and sync is off.

 

[brttc]

Thanks, any tips on making the correct adjustments? I'm guessing that that follower cam should be sitting all the way forward or all the way back. Mine sits near he middle. I am mechanically inclined, but don't know where to start making tweaks here

 

[flyingscott]

Disconnect the throttle cable and take a pic of the throttle assembly with it off

 

[brttc]

Unfortunately it's too late for that. I've already disconnected and adjusted more than I should have. My manual won't be in until next week. I'll post pictures of where I'm at when I get home of where I'm at. Here's what I did:


Set the throttle cam roller to the white mark at idle.
Adjusted the idle stop to actually touch
Adjusted the timing link (I made a mistake)...

What is a good starting length for the timing link? I should've counted the threads!

 

[flyingscott]

Ok to do the link and sync take the throttle cable off of the linkage. Back the idle screw out so it is flush you will not adjust the idle again until the sync is done. Push the throttle back as far as it will go, now adjust the long rod until the roller lines up with the line on the cam. Don't let the linkage come forward while you are doing that. You will now need to adjust the throttle cable to line up with the linkage where it is after the adjustment. After you get it started you can adjust the idle screw you will also need to adjust the throttle cable while you are adjusting the screw. You will need to make the final adjustments on the water when the motor is warm. I will try to get you a rough measurement for the timing linkage tomorrow, but you will still need to have a dealer time it.

 

[brttc]

Flyingscott, I really appreciate the help... Thank you, just wanna get it close and make sure the motor runs so I just need a rough starting point on that timing link. I'm glad you mentioned the roller because every manual I've looked in this far had me lost, I assumed it lined that up to the "neutral" position. Should make a lot more sense now, thank you.

 

[flyingscott]

The motor does need to be in neutral for the link and sync. My timing rod (the upper short one) measures 1 15/16" between the connectors. That is how much rod is showing.

 

[brttc]

Ok thanks. This is the problem with it being that short.... I adjusted it to the factory 4.25" "Eye to Eye" and am noticing the idle wire is jamming up the linkage. I can keep it that short but have to move my throttle cam forward. Please see pictures below:
IMG]http://i66.tinypic.com/10gbgc5.jpg[/IMG]
Dogbone measured (timing link)

1 15/16"

Total length

Beginning the synch/link. Removed all rods and held throttle closed against the carb

Holding throttle linkage back. In the mean time I was adjusting the throttle cam rod to fit the cam roller between the white line

Forgot to take a picture of it aligned, but it is correctly centered between the white lines.

After inserting the timing link, you'll see that my idle wire is getting jammed. It will not work at the current position of the timing link

Another image of the wire below

This is where the linkage will bind because of the idle wire.


Any suggestions?

 

[flyingscott]

Ok ,turn the knob on the front of the motor all the way to the left that will loosen the wire or push the knob in. 1 15/16 comes out to 1.9375. You also need to disconnect the throttle cable. That long rod to the carb needs to be much shorter.