60hp Mercury intermentant problem - Mechanic so far let me down

Joined
Feb 20, 2011
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I have a 1991 - 94 60 hp mercury with 3 carbs. This problem is intermitant. Usual top speed is 30 mph. Problem is sometimes it loses power and won't go faster than 5mph. Plugs are new. Squeeze bulb has pressure. Mate has cleaned Carbs - and later so apparently did the Mechanic. Tank is vented and clean. Problem may last ten minutes or half a day when it suddenly begins to clear it's throat and slowly pick up speed and runs fine until next episode. This problem has gone on for 12 months. I am at a teather..... New fuel line, New bulb,new kill switch , new ingnition barrel, yes petrol tanks and filter was cleaned/replaced more than once Does this sound like a carb or electrical problem - I am sure a fuel problem? Or what else??? Please I need assistance I have spent over $1000 at the Mechs and still the problem raises its ugly head.
 

jerryjerry05

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May 7, 2008
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18,089
Re: 60hp Mercury intermentant problem - Mechanic so far let me down

How old is the pump? Check for soft hoses.Clogged filters.A new squeezie can be bad.Are there any inline connectors? It could be sucking air.
 

CharlieB

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Apr 10, 2007
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5,617
Re: 60hp Mercury intermentant problem - Mechanic so far let me down

When the condition begins, immediately shut down long enough to UN-plug the two yellow wires from the stator to the rectifier.

Restart and see if that makes any change/improvement.

If yes, replace the rectifier.
 

Faztbullet

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Mar 2, 2008
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15,931
Re: 60hp Mercury intermentant problem - Mechanic so far let me down

I have a 1991 - 94 60 hp mercury with 3 carbs
Going to need more information that this as these year motors could have CDM modules,pack,Red or Black stator,ignition adapter,over rev module,all which make a difference in troubleshooting. It sounds electrical to me. If its the pack style check the grounds as these where bad about losing connection due to so much wiring stuffed in small slot.
 
Joined
Feb 20, 2011
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Re: 60hp Mercury intermentant problem - Mechanic so far let me down

Cheers for repy.
Hoses are new. Fuel filter is new. Squeezie is new but had problem before I replaced it. Fuel line in motor has been replaced also. All connections are super tight so not saying not the problem as I may have missed something but I think I will need to look behond that - Keep the ideas up though please :)
Forgive my ignorance but what pump? The fuel pump - I have not looked at this yet. I was discussing that with someone just the other day. I was told to disconnect the pump and raise the level of the fuel tank to let gravity take its place? Thanks for your reply.
 
Joined
Feb 20, 2011
Messages
6
Re: 60hp Mercury intermentant problem - Mechanic so far let me down

When the condition begins, immediately shut down long enough to UN-plug the two yellow wires from the stator to the rectifier.

Restart and see if that makes any change/improvement.

If yes, replace the rectifier.

It only plays up while on the water for a constant hour or 2? I have replaced the wiring as they were originally all green in the connections. Unfortunately I may have made a mistake by soldering all wires together? I like your idea but will require some planning on my behalf as I may have to add some connections so when on the water I can check this.......The rectifier is that the black box the wires run too from the stator?
 
Joined
Feb 20, 2011
Messages
6
Re: 60hp Mercury intermentant problem - Mechanic so far let me down

Going to need more information that this as these year motors could have CDM modules,pack,Red or Black stator,ignition adapter,over rev module,all which make a difference in troubleshooting. It sounds electrical to me. If its the pack style check the grounds as these where bad about losing connection due to so much wiring stuffed in small slot.

I am going to have to look into this to answer your question - Maybe I can post a picture - will that help? Youve thrown me on ignition adapter, over rev module,CDM module,pack, red or black stator. Maybe I will do some more searches on the internet to work this out - looks like I am going to have to continue educating myself. Thanks Captain!
 
Joined
Feb 20, 2011
Messages
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Re: 60hp Mercury intermentant problem - Mechanic so far let me down

Thankyou everyone for your ideas. I have never used a sight like this and I am excited to see the replies. I am no mech but would love to knuckle this prob out with assistance. I have spent over $1000 at the workshop and still the prob is not fixed so I am hessitant to go back to a dealership at the moment ( My wife will kill me if I keep throwing money at it with no result!)
 

abdunbar

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Aug 14, 2010
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Re: 60hp Mercury intermentant problem - Mechanic so far let me down

Did you solve this problem?

"I have a 1991 - 94 60 hp mercury with 3 carbs. This problem is intermitant. Usual top speed is 30 mph. Problem is sometimes it loses power and won't go faster than 5mph. Plugs are new. Squeeze bulb has pressure. Mate has cleaned Carbs - and later so apparently did the Mechanic. Tank is vented and clean. Problem may last ten minutes or half a day when it suddenly begins to clear it's throat and slowly pick up speed and runs fine until next episode. This problem has gone on for 12 months. I am at a teather..... New fuel line, New bulb,new kill switch , new ingnition barrel, yes petrol tanks and filter was cleaned/replaced more than once Does this sound like a carb or electrical problem - I am sure a fuel problem? Or what else??? Please I need assistance I have spent over $1000 at the Mechs and still the problem raises its ugly head. "

I have the same motor. Just had it out today. Did not use stabil or drain carbs last fall.
Drained old gas, put new. motor started right up but would not accelerate. Under power it would stall around 2000 rpm. after about 20 minutes of running, it would work slowly up to full speed if I let it creep up very slowly. Ran fine for about 10 minutes at full throttle out in the lake. Came back to the dock area, lots of wind and didn't want stranded in the lake, tried again to accelerate, same issue with stalling. this time would not accelerate at all. Motor would just die if the throttle was pushed to full.

I am guessing needs carb cleanout, probably main jets obstructed. so opening throttle leans the mixture and it stalls.

I have had these carbs apart before. I think you can get to the jets from the side without disassembly. I am going to take that brass plug in the side that covers the main jet out and see what drains out of there. I'll catch it in a small glass bowl. That would be the quick fix. if that doesn't work, I've got three rebuild kits in my tool box.

Archie
 

abdunbar

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Aug 14, 2010
Messages
3
Re: 60hp Mercury intermentant problem - Mechanic so far let me down

OK, it wasn't the jet, not exactly, took apart the carbs and their was a bunch of debris from the old fuel clogging up the fuel pickup in the float bowl. = varnish in the float bowl.
 

60hpmercguy

Cadet
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Aug 13, 2011
Messages
16
Re: 60hp Mercury intermentant problem - Mechanic so far let me down

Hello abdunbar, I have exactly the same problem with my 1996 60 HP mercury. Have you found the problem yet? I'm still trying different things here to fix it.
Mike
 

Jeep Man

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Joined
Oct 17, 2008
Messages
2,803
Re: 60hp Mercury intermentant problem - Mechanic so far let me down

OK, it wasn't the jet, not exactly, took apart the carbs and their was a bunch of debris from the old fuel clogging up the fuel pickup in the float bowl. = varnish in the float bowl.
Abdunbar, you should start your own thread. Not cool to hijack jeremy's.
 

reynold460

Petty Officer 2nd Class
Joined
Apr 25, 2008
Messages
103
Re: 60hp Mercury intermentant problem - Mechanic so far let me down

run motor then shut down pull plugs to see if you have water getting into the cylinders look for water droplets or milky substance on plugs i had the same prob and it was water gettin into cylinders
 
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