1975 Evinrude 25hp misses after warm-up

jugdish

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I recently cranked up my 25hp Evinrude motor. It started on the second pull and ran fine for the first couple of minutes or so. Then it died as if I hit the kill button. I restarted and again after about 20 seconds, it died abruptly. I restarted and ran it a little faster (almost max throttle in neutral) and it doesn't die abruptly. But, it randomly misses - much like before - like I pressed the kill button for split second. It still has enough momentum to keep running since the ignition miss is somewhat instantaneous. <br /><br />More background: A few years ago I had the motor virtually rebuilt including much of the ignition system. I didn't use the motor for nearly a year after it was serviced. When I finally used it, it worked fine for the the first few hours of usage. The next time I used it (a few months later), after the motor got warm, it started this missing problem. At high speed, you could occasionaly experience the miss. But at low speeds, the miss would cause the engine to kill.<br /><br />I let the engine sit again for about a year or so. That brings us up to date - last week, when I put the motor in a makeshift tank and cranked it right up. I did put in fresh plugs, new gastank, hose, gas, oil, etc. I also hit the carb with a few shots of carb cleaner. Anyway, it started right up and ran fine for a couple of minutes then started missing occasioning - killing the motor at normal idle speeds.<br /><br />If I momentarily press the kill button while the motor is running normally, it mimicks the ignition 'miss' that I've tried to decribe.<br /><br />Please offer your thoughts on how I might troubleshoot/repair this problem. Thanks.
 

fireman57

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Re: 1975 Evinrude 25hp misses after warm-up

Are you sure that it is not overheating? You may need to replace your impeller and make sure that the cooling lines are clear. If you have tstats in this engine you might want to consider replacing them. When you had the engine "rebuilt" was it done my a mechanic or a friend. You could have a sheared flywheel key if it was not torqued down properly. Also do not run this engine at high rpms in neutral unless you don't want to keep it very long. Since it sat for good bit I would start by removing and totally cleaning the carb and put a rebuild kit in it. Doesn't take long for the gas to varnish up anymore. Make sure that you use Stabil in it if if is going to sit for any length of time. Also, it is only good for about a year.
 

jugdish

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Re: 1975 Evinrude 25hp misses after warm-up

Thanks for your reply, fireman57. <br /><br />Yea, I'm pretty sure it's not overheating. Plenty of water in the exhaust and out the pee holes. It was serviced in a shop - a reputable one. The water pump and t-stat were replaced during that shop visit. It only has to idle about a minute or so before it starts to miss. <br /><br />I pulled the plugs and both are wet but the top one is much, much cleaner than the bottom one. I suspect the top one is not firing consistently?<br /><br />I agree a good carb cleaning is in order and plan to do so shortly. But my gut feel is that the missing is due to an ignition problem. Thoughts?<br /><br />About the RPMs, max throttle in neutral seems mechanically limited and it's not really 'fast' at all - just a little faster than normal idle speed. Unless it's just running on one cylinder...<br /><br />Thanks,<br />Jug
 

BF

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Re: 1975 Evinrude 25hp misses after warm-up

a few thoughts...<br /><br />dirty points?<br />maybe a cracked ignition coil? <br />maybe if ignition coil was replaced, the wire wasn't tucked down far enough, and the flywheel wore our the insulation? (been there, done it)<br />maybe the idle mixture is set quite a bit too rich, and it's too rich to run once it hits operating temp? (not too likely, yes it sounds like an ignition problem to me based on how you describe it)<br />maybe cracked wire in kill switch circuit, or bad switch causing momentary shorts?<br /><br />I would guess one of the first 3, but probably try jiggling the kill switch wires before I pulled the flywheel. <br /><br />What kind of shape is the rubber in the "kill" button like? On mine (earlier year), the springiness of the rubber button itself is what keeps the contacts in the stitch from being closed all the time. Maybe the rubber button is rotten and the contacts are very close together (?).<br /><br />I think I'm out of ideas!<br /><br />good luck.<br /><br />Brent
 

fireman57

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Re: 1975 Evinrude 25hp misses after warm-up

Check your spark on this machine. Pull the wires one at a time with well insulated pliers when it starts missing and listen for a change in rpms. I agree with BF on checking your coils if you find you have dropped a cylinder.
 

jugdish

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Re: 1975 Evinrude 25hp misses after warm-up

Thanks for the inputs. I'll try to check the spark today and report back. <br /><br />I think all the ignition components were replaced including the coils and wiring during the recent service visit. I briefly examined the wiring and didn't see any obvious opportunity for leaks. I will check the kill switch too. <br /><br />The theory about the flywheel wearing thru the insulation sounds like it could explain things. I need to get brave enough and pull the flywheel and see what's going on under there too.
 

jugdish

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Re: 1975 Evinrude 25hp misses after warm-up

Ok, looks like I'm getting spark to both plugs. After a bit of anxiety I got the flywheel pulled and didn't notice anything unusual. Everything looks new and clean - no obvious leaks or wear in any wires either. <br /><br />Btw, the kill switch seems to be in good shape too.<br /><br />I also tried another new set of plugs and after just a couple of minutes of running I pulled the plugs - top plug is relatively clean and the bottom plug is dark, both slightly wet.<br /><br />What should I try next? Please advise.
 

jfm1

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Re: 1975 Evinrude 25hp misses after warm-up

do a compression test. maybe a head gasket leaking '
 

fireman57

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Re: 1975 Evinrude 25hp misses after warm-up

Since your bottom plug is dark and wet I would suspect a weak spark to that plug, hence your miss. Spark has to be bright blue, not orange or yellow, to fire under a load.
 

jugdish

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Re: 1975 Evinrude 25hp misses after warm-up

Well I did a compression check and each cylinder recorded about 90 psi (+/- 1 psi). <br /><br />Regarding the spark, I will need to go recheck the 'color' and report back.<br /><br />Is it possible for the carb/manifold to supply air/fuel mix differently to each cylinder on this motor?<br /><br />Any other ideas are certainly welcome...
 

fireman57

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Re: 1975 Evinrude 25hp misses after warm-up

You only have the one carb and it supplies both cylinders. It should supply both equally. You may a stuck float in the carb and it is just running out of gas and dying. When it sits for a second the float drops and the carb refills and engine starts again. This engine has sat on a couple of occasions and could have a fouled carb. I would go ahead and rebuild the carb with the 20.00 kit from the dealer or this site. The reason I wanted you to check spark first was to eliminate it before you started taking things off this engine and throwing money at it. It's a good engine and will serve you well. Run Stabil or a like product in every tank. You might also consider running a little Seafoam in each tank. When it starts to die pump your primer bulb or have someone shoot some premix in the carb with a sprayer bottle and see if it takes back off. One last thing, did you torque the flywheel back down to specs? If you didn't you will shear your flywheel key and it might start but you won't go anywhere. Torque spec should be in the manual that neither of us seems to have.
 

jugdish

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Re: 1975 Evinrude 25hp misses after warm-up

I pulled the carb and disassembled it somewhat. It's soaking in a carb chem bath overnight. But I have to say that the gaskets were like new and everything was spotless inside... I didn't see any signs of varnish. The manifold looked spotless too.<br /><br />I'll report back when I have the carb rebuilt and tested.
 

jugdish

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Re: 1975 Evinrude 25hp misses after warm-up

I looked more at the coils and concluded they were NOT replaced during the last service visit as I previously thought. I did notice some cracking and drooping in the insulation. When I removed the lower coil, one of bolts was frozen into the head. Needless to say, I broke it off. I tried using an EZ-out bit but broke it off in the remainder of the screw.<br /><br />Any suggestions on how to remove this broken bolt with an EZ-out tip embedded in it? <br /><br />I'd really like to get the new coils on, check the points gaps, then crank this thing up with the rebuilt carb.
 

jugdish

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Re: 1975 Evinrude 25hp misses after warm-up

I finally installed the new coils. I also checked the points gap and one set was about half of what it was supposed to be. I found the adjustment to be rather flimsy - should I be able to adjust the gap while the points are screwed down tight?<br /><br />Anyway, got the motor running and it ran at fast idle for over 5 minutes without stalling. It still seems to run a little rough but maybe it's just good ole vintage '75 two-stroke performance?<br /><br />I'm gonna try to get it into the water soon to give it a little test run.<br /><br />Btw, a nice pricey carbide bit did the trick drilling out the EZ-out.
 
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