1970 evinrude lightwin 4 hp not running smoothly at high rpm

someone1357

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Jul 24, 2010
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I cleaned the carburetor, I re-cleaned the high speed jet, I replaced the spark plugs, I checked the spark (was fine), I replaced the ignition system, I set the spark plug gaps to .030" and the points to .020", and the motor idles amazingly well, but when I ramp up the throttle to full speed, the motor's speed fluctuates eg. 5 seconds at full rpm/speed, 5 seconds slower (enough to take my 8' boat off of a plane), and then back up again etc.... I have no idea what the problem is, and this thing is really starting to get me angry. ps.if I turn the high speed needle valve counter-clockwise for a richer mixture, the problem lessens, but the motor does not run at full rpm.
 

Rick.

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Re: 1970 evinrude lightwin 4 hp not running smoothly at high rpm

I sounds like one of your coils might be giving you an interrupted spark. What was the physical appearance of your coils when you had the flywheel off? If you saw any cracks they should be replaced. But I've not heard of a bad coil giving that kind of a rhythmic problem as in 5 good, 5 bad. Still if they are cracked get them out of the picture.

From what you say about turning out your high speed jet it makes me think it is a fuel related issue. Your needle could be sticking or your float not set correctly. Either could give you intermittent fuel problems. You mention cleaning your carb. but you don't say you put a kit in it. Forty years of service might dictate that it's kit time. Let us know and don't get mad. Just keep plugging away and you will win.

Everything you've done to this point has been worth while and you have eliminated a number of possible weak spots.

You haven't given any history on the motor which could be helpful. Best of luck. Rick.
 

someone1357

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Re: 1970 evinrude lightwin 4 hp not running smoothly at high rpm

okay, I was in a bit of a hurry while writing about my problem, here are the anwsers to your questions. 1. coils: along with the points, capacitors and other parts that go on the magneto under the flywheel I replaced both coils with brand new ones. 2. yes, when I cleaned the carb I put in a new kit. I could possibly take the carb apart again and see if the float is sitting correctly...

I should also mention, I just checked the compression about 15 minutes ago and the gauge read 93 psi in the top cylinder and 91 psi in the bottom cylinder. I'm not very experienced with this kind of stuff but I think that seems pretty good for this size of motor...

as for history... I bought this motor off someone on craigslist for 160$, he gave me a demo in a barrel before I bought it, and it ran farely well (he was running it on a 40:1 mix, I now run it at 50:1) I don't remember if it was having the high speed problem at that point in time though... he also changed the gearcase oil when he bought it. He said he had owned it for about 3 weeks, before that he bought it from another guy who was the original owner of the motor. upon inspection from top to bottom, everything looked okay, corrosion on the prop most likely from running it in salt water, the top and the bottom part of the motor was re-painted a while back, I know it was a while back because the paint was coming off in some places, I looked at the engine and it looked like it was re-painted as well, though i'm not sure. Upon lifting the flywheel I found an old, cracked coil that seemed to have salt water corrosion on it, and another newer coil that was replaced by the guy I bought the motor from, I replaced both. all the ignition parts (points, capacitors) looked okay, I replaced them anyways... I then put the flywheel back on, and put the cover back on the motor and noticed that it had been re-painted, possibly to cover up a dent/crack I noticed on the corner, indicating that the motor may have been dropped.....



anyways, sorry about the long post, but to summarize, what do you suggest I do at this point?

[UPDATE] the fluctuations in speed werent exactly 5 secs up, 5 secs down etc... it changes, say sometimes 5 seconds up, 3 seconds down, or 7 seconds down, 4 seconds up (if you understand what i'm trying to say at all) the 5 seconds up/down was just an average.

[UPDATE #2] I also forgot to say that the fuel tank I purchased seperately from someone else was covered in varnish on the inside because it sat so long, so I sprayed a quarter cup carb cleaner in the tank with a quarter cup fresh gas, put a chain in, and shook it to free up the varnish, I then poured out the varnish, carb cleaner, and gas. I then put in a cup of gas and swished it around to get anything off the walls, though there may have still been some varnish/carb cleaner solution in the tank when I filled it up and ran the motor off of it, though I would imagine that would not be the source of the problem, since it would be so diluted it would be pretty much impossible to notice.
 
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Rick.

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Re: 1970 evinrude lightwin 4 hp not running smoothly at high rpm

You've been very thorough in what you have done. I think your compression is just fine. One more thing that comes to mind. I would suggest new gas lines from the tank to the carb. paying special attention to making sure all connections are tight and not leaking any gas/air. Did you replace the packing washers on the high speed needle and did you tighten the packing nut that the needle goes through? You could be getting an air leak right at the needle. Rick.
 

someone1357

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Re: 1970 evinrude lightwin 4 hp not running smoothly at high rpm

I don't quite remember if I replaced the packing washers... though I should probably try tightening the packing nut that the needle goes through. It is quite easy to move the high speed needle (just a light touch will move it) I should probably point out that if I tighten the nut a bit, then unscrew the high speed needle and take it out of the carb to clean it and spray the hole it was in with carb cleaner, after I put the needle back in it becomes easy to turn again. My only question is how would an air leak cause fluctuations in speed, would it not just slow the whole motor down? and as for the fuel lines, I recently checled them and nothing is leaking, though there is nothing holding one of the fuel lines to the fuel filter/pump. I could put something there to tighten it up, though it was not leaking any gas before.
 

someone1357

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Re: 1970 evinrude lightwin 4 hp not running smoothly at high rpm

I tightened the packing nut quite a bit, but the motor is still having the same problem. I noticed that the low speed needle squeaks when I turn it, so there may be a rubber gasket there, but the high speed needle does not squeak, so maybe there should be a rubber gasket somewhere there as well?
 

Happy_Jack

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Re: 1970 evinrude lightwin 4 hp not running smoothly at high rpm

Possibly sucking air at on (or both) of the adjustment needle packing joints.

Did you pull the needles out of the carb when you did your rebuild, and remove ALL the old needle packing material, then replace with new packings? (usually 2 packings per needle works well)
I usually put a little mystery oil on the packings when I put them in to ensure easy movement of the needles as they are re-inserted and screwed in past the packings, as well as for ease of turning when making adjustments.
Once they are initially set, dial them in, then tighten the packing nuts firmly to ensure there are no air leaks.

Other than that, maybe one little piece of crud is elusive enough to cause the searching RPM issue.

Did you remove all of the welsh plugs and spray/blow out all the passages when you rebuilt, then replace with new welsh (or is it welch) plugs?
 

someone1357

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Re: 1970 evinrude lightwin 4 hp not running smoothly at high rpm

it's been about a month since I bought this thing, I did the carb rebuild right when the parts came (not long after I bought the motor) and I only just started running the motor... I do not remember if I replaced the needle packing material or replaced the welsh plugs. I'm going to open the carb back up again today and see what I can find, and will report back after re-cleaning it what I saw.

[UPDATE]
I believe I have found the source of the problem. I took the carburetor apart and I noticed that the rubber gasket that the packing nut was pushing against to stop air from leaking in/out was extremely worn out, it came out in pieces when I tried to remove it. Since I do not have a replacement gasket of the right size, I will go to the hardware store today and buy one that fits if I can find one. I will report back when I have the motor running. everywhere else inside the carburetor was completely clean, with no gunk or anything.
 
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someone1357

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Re: 1970 evinrude lightwin 4 hp not running smoothly at high rpm

okay, I replaced the high speed needle gasket/packing? and put everything back together, and the motor runs. I ran it @ WOT and the problem seems to have disappeared, though I'm not absolutely sure because it's own exhaust could be suffocating it. I'm gonna run it on the lake in a bit and I will say if the problem is really gone. I want to thank "Rick." and "Happy Jack" for your help with my problem so far.
 

Rick.

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Re: 1970 evinrude lightwin 4 hp not running smoothly at high rpm

Appreciate your thanks but I have to say everything I've learned about outboards has been through the knowledge of shared experience from the members of this fantastic forum. I hope all goes well tomorrow and please do let us know. By the way, you should not be running at WOT in a barrel. Only run your engine at faster speed when your on the lake and it's under load. You may have to re-adjust your needles a little due to increased back pressure on your exhaust. Rick.
 

someone1357

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Re: 1970 evinrude lightwin 4 hp not running smoothly at high rpm

Okay, I got out on the water and ran it, and it works great. No problem whatsoever. Runs smoothly at all speeds. Thanks for the help, I definitely got my 160$ worth from buying this motor, except for the fact that I ended up putting about 7 hours of work into it...
 

Rick.

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Re: 1970 evinrude lightwin 4 hp not running smoothly at high rpm

Seven hours is a small investment IMO. Glad to hear it's working well for you. They run forever on a tank of gas. So cheap I had to start mixing smaller batches so the gas would be fresh. Rick.
 
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