92 OMC Cobra 5.0l Stalls Under Load

bdeweese

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Jul 15, 2009
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I have a 92 FourWinns with OMC Cobra 5.0l and 2v Holly Carb that runs great for the most part - with one annoying exception. I have had the boat for appx. 6 years and have had this problem that whole time.

Engine starts fine, warms up fine and when underway - runs great. RPM's top out around 5000 which I think is about right for this setup. The nagging issue is that whenever we are sitting idle in the water getting ready to tow a skier, tuber, wakeboarder, etc. and then "hit it" to pull them up, etc. the motor will stall. The workaround has been to "baby" the throttle at first and then once it has a bit of speed crank on the rest of the juice needed. This works fine and once we're rolling the boat just runs like a top. But I feel like I shouldn't have to "baby" the thing and after 6 seasons it's getting old.

I have never had any issues of it missing, stalling at faster speeds, problems starting, etc. It's just this one very annoying issue. I have had it into the dealer several times over the years (FourWinns - same folks that originally sold and serviced this boat when it was new back in 1992).

Of course every time they would test the motor (not under load) they would tell me how great of shape it is in and how well it runs. They could never find any problems under normal shop testing. Last year I finally got them to take it out on the water and they were able to duplicate the problem. However, after messing around with the carb and saying "try it now", nothing improved.

Finally I decided to replace the carb (myself) - got a refurbished one straight from Holley - factory tested and set, etc. Very easy swap. Started right up, runs like a top - and of course - still cuts out when first start moving under load. I would suspect a timing issue - but then it would seem to me that that would have been pretty easy for the dealer to diagnose and solve - so makes me think it's something less obvious.

So - Unless I'm overlooking the obvious, that would seem to rule out the carb as the culpret. Where would you guys have me start? Any likely culprits? I've been reading the forums for awhile now but this is the first time I've posted. Thanks in advance for any ideas. Let me know if you need any other particulars.

Thanks! Bob
 
Joined
May 31, 2009
Messages
22
Re: 92 OMC Cobra 5.0l Stalls Under Load

Hey Bob you said it tops out @5000 rpms is the motor stock? Will it do it while it is cold or only after it warms up. It sounds like acelerator pump have you checked to see that the pump is squirting soon as the flaps are opening?
 

bdeweese

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Re: 92 OMC Cobra 5.0l Stalls Under Load

It's stock. I will need to take a look at the tach again tomorrow when we take the boat out again. I was going from recollection that my top rpm's are around 5000 but I could be mistaken. I have had it up close to 50 with light load and boat trimmed out and it seemed like the rpm's were right around there.

It does it even worse when it is cold - it seems a little less temperamental when it's warmed up - but still does it consistently. But I can be a bit more aggressive on the take off once it's good and warmed up. If the problem went away altogether at that point I would just assume it is slow to warm up. But it never really goes away.

I haven't checked out the pump to make sure it is working properly. Is there any special way of doing that? Thanks for the help!
 
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wanna-be

Petty Officer 3rd Class
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Jul 12, 2009
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Re: 92 OMC Cobra 5.0l Stalls Under Load

could be pump or maybe the interrupter switch or shift cable needs adjusting. ck your manuel to find these.
 
Joined
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Re: 92 OMC Cobra 5.0l Stalls Under Load

no, no special tool just have some one at the controls to give it gas while you look down the carb.soon as the linkage starts to move the pump should start to pump fuel. do also check the esa and cable adjustment as stated by wanna-be
 

bdeweese

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Re: 92 OMC Cobra 5.0l Stalls Under Load

The pump appears to be squirting fuel right from the get go, so that appears to be fine. On to checking out the Interrupter switch or shift cable adjustments. I took it out yesterday and wide open with boat trimmed out and a load of 6 people the motor turned between 4700 and 5000 rpm's.

I messed around with it some and determined that if the boat is at a dead stop with no tuber or wakeboarder in tow, I can "hit it" and boat responds appropriately with no stalling out. But as soon as I add any additional tow load, the problem appears - so it's definitely aggravated by the additional load on the boat. If I just simply start out a bit slower on the take off it works fine.

I'll keep you posted. Thanks again for your replies.
 

Gary H NC

Fleet Admiral
Joined
Dec 1, 2005
Messages
8,972
Re: 92 OMC Cobra 5.0l Stalls Under Load

Still could be a weak accelerator pump in the carb. How long has it been or has the carb ever been rebuilt? Its just a rubber plunger and they do wear out.
 

a70eliminator

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Sep 9, 2007
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Re: 92 OMC Cobra 5.0l Stalls Under Load

The first post stated that he had already replaced the carb with a factory refurbished one from holley.
 

bdeweese

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Re: 92 OMC Cobra 5.0l Stalls Under Load

I just put the carb in a week ago - it came straight from Holley as a "factory refurbished" - so the pump shouldn't be the problem. Not to say it would be impossible for it to be a defect - but this would be the same symptoms for 2 carbs in a row so it seems a bit unlikely.

Today I went through all of the shifting and throttle cable checks as well as checked the interrupter setup. So far everything checks out. The interrupter is in the right positions and when I put it on an ohmmeter I got the proper readings in all positions. I am going to need to water test it since the adjustments and see if anything changed. I also replaced the fuel filter today just to be on the safe side - it was due anyways. But I don't think it is the cause of this problem.

Will report back and let you know if anything changed. Thanks again!
 

wanna-be

Petty Officer 3rd Class
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Jul 12, 2009
Messages
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Re: 92 OMC Cobra 5.0l Stalls Under Load

interrupter switch only works when under load but doesn't sound like thats the problem, but the lower shift cable might need adjusting. rpms are in range. because it only happens when under heavy load, you might try a lower prop pitch... current prop maybe too much stress.
 

bdeweese

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Re: 92 OMC Cobra 5.0l Stalls Under Load

I switched out props way back when at the dealer's suggestion in response to this same issue - but it's been quite awhile and I honestly don't remember what is on there. That would be a simple enough solution if it is indeed the problem.

Any suggestion as to what prop I should be running? I am willing to lose some top end if it means getting out of the hole more easily. I know I currently run a 3 blade (NOT stainless) but will need to double check the size and pitch.

Thanks! Bob
 

Offrddrver

Petty Officer 3rd Class
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Sep 19, 2009
Messages
95
Re: 92 OMC Cobra 5.0l Stalls Under Load

Bob,

First, I have this exact same issue with my 1992 190 Horizon Four-Winns, 5.0L (Ford 302) OMC setup. It has a Holley 2-BBL Carb (List # 80386)

I've been through nearly your exact troubleshooting plan as explained in your blog. I changed from Aluminum Prop 14.5 X 19 to an OMC 15 x 15 Stainless Prop (P/N: 174926). This prop is great for pulling HEAVY slalom skiers out of the hole with ease, but this was NOT the solution to my Stalls Under Load issue. In fact I think this prop contributes to the stalls under load issue (but is not the root cause.)
I rebuilt my Carb with the proper JET size for PHX, AZ elevation which helped with top end speed, but there was no change to the Stall under load issue.
(In short, I highly doubt a carb issue as you have a new/refurbished unit direct from Holley.)

Here is what I believe to be the issue as I had it "FIXED" at one point, and then the issue came back after I completed work which required removing and reinstalling my outdrive.

When there is ZERO load on your prop (during driveway testing) it will not happen. (as noted by your dealer at the shop) When you put the boat in the water it has minimal load so it rarely if ever happens without a skier or tube. My issue got worse when I changed from the smaller prop and went to the bigger S/S. prop. MORE LOAD on the out drive.
I found that the extra load on the outdrive migrates back through the linkage, which just barely moves the "Y" metal rocker piece. It then barely trips the cut out switch until the boat gets up to some minimal speed.
It then relaxes that "Y" metal rocker and releases the cut out switch. At this point your boat ramps up in RPM and speed with no issues.

I tried making adjustments to linkage, but this always resulted in new issues. I adjusted the linkage until the stall went away, but then the cut out switch trips when in reverse. As if you cannot find a happy medium with this linkage. So I brought it back to the original linkage position, which returned the Stall Under Load issue, but fixed the reverse issues.
I pulled the "Y" metal rocker piece from the linkage (Top Driver side of motor) and located the "V" shape spring under it. I very lightly spread out the "V" shape spring. This allowed the "Y" shape rocker piece to return to the center position even with more load.
HOWEVER, YOU HAVE TO BE CAREFUL with this adjustment, because too much spring load does not allow the cut out switch to trip at all. This may lead to issues with the out drive not shifting smooth.

This resolved my issue for about two years.
Then I changed my gimble bearing and U-joints which required I remove the out drive. This required motor position adjustment to properly align the motor and drive shaft. I think this resulted in movement of the linkage enough that the Stall Under load issue started.
The STALL UNDER LOAD issue returned, but this time only with a Skier or tube, and only right at the whole shot. I've reduced the issue with VERY minor linkage adjustments, but still not 100% issue free. Try 1/8 turn on linkage adjustment and then confirm reverse is still working. Then try pulling a skier or tube. Repeat until issue resolved or reverse no longer runs without the cut out switch tripping. MAKE SURE TO MARK EVERYTHING BEFORE ANY ADJUSTMENTS ARE MADE! If the issue is not resolved or greatly reduced then I suggest the spring adjustment.
I'll be adjusting the spring load on my boat again as the minor adjustments did not FIX the issue 100% for me.

Overall I think this spring load design on the "Y" shape rocker is JUNK.
WHY..... Because it relies on a spring that can lose its shape or load tension over time. You may FIX it this year, but in a year or two the issue may return due to the spring.

Sorry so long, but I wanted to explain my work in detail.
Please keep me/us posted on your final repair as I am also very interested in someone else?s solution to this issue.
By the way, if you read enough blogs about the OMC linkage you will see a couple things.
1. Everyone says to have a professional complete the linkage repair.
2. Everyone that had a professional make the repair had the same issue at a later date. Fairly soon if not immediately after "REPAIR".
3. In most cases the professional states that the cable is stretched and requires change.
4. Most people report the same issue even after the cable is changed.
Again, this sounds like bad design when you boil it all down.
I looking at making a new location for the cut out switch on my boat as I'm also fed up with this Stall under load issue.

Regards,

Offrddrver (Off Road Driver)
 

Lou C

Supreme Mariner
Joined
Nov 10, 2002
Messages
13,156
Re: 92 OMC Cobra 5.0l Stalls Under Load

One thing not mentioned...make sure you are gettting full spark advance at the specified RPM...if not then you could have this problem...
And another thing to check...any restrictions in the fuel system...vent....anti siphon...filters..etc...
 

Offrddrver

Petty Officer 3rd Class
Joined
Sep 19, 2009
Messages
95
Re: 92 OMC Cobra 5.0l Stalls Under Load

Bob,

Just to note....
My 1992, 5.0L (Ford 302) Four-Winns, 190 Horizon, OMC cobra turns 4000 to 4600 RPM @ W.O.T. (based on the trim position when in the lake)
Spec for this motor/drive combo is 4000 to 4400 RPM in my manual and 4000 to 4400 on the official OMC sticker that is mounted on the driver side exhaust header.

My smaller prop turns nearly the same RPM, but the whole shot would never pull a large slalom skier out of the water without dragging them first (I hate that.) That is why I went to the larger prop.

My small prop runs the boat at 47mph, with only the driver and a full load of fuel.
My large "ski" prop runs 42 mph no matter the load size. (within normal limits of coarse....usually 4 adults max and 3 to 5 kids & full fuel)

If it is a Ford 302 then I think you may be a bit high on the RPM, but if you are running 50 mph top end and still have a good whole shot then in my book....sounds great. If you are dragging your skier then you have lots of room for a better "WHOLE SHOT" prop that may only cut 2-3 mph off the top. That is still good speed.

Can you tell us your prop make, size, ect?


Regards,

Offrddrver
 
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