Evinrude 9.9HP 4 stroke

[roehrle09]

Bought a 1997 new 4 stroke and have had 12 years of problems with this motor. Just wondering if anyone else on this forum has this motor and would like to compare notes. For those interested in buying an used unit I would be extremely careful

 

[JB]

Re: Evinrude 9.9HP 4 stroke

I had a '97 Johnny 9.9 4 stroke, which is the same girl in a different dress.
It was a sweetheart. Never gave me a minute of trouble. I did all of the maintenance using a factory Service Manual.

Often machinery gets a lemon reputation because of incorrect maintenance.

Tell us about your 12 years of troubles. Perhaps we can get her well for you.

 

[roehrle09]

Re: Evinrude 9.9HP 4 stroke

OK,remember you asked for it:
April.1997
The very first day I took my brand new boat out for a test run after about one hour the motor started to cut out. It would start up and run for a few minutes and this time became shorter as I headed back to my port. I barely made it back. I took the 114lb motor off which is a nasty job while the boat is in the water. It was back at the shop for a couple of weeks.
June 14,1997
They replaced the electronic power unit at no cost to me.
No problems during 1998
May 1999
Motor would not start so I again returned it to the dealer
July 5,1999
Replaced the power unit again, at no cost.
Near the end of the 1999 season the motor started stalling again when ever it ran over 1/2 hour.
Took back and they once again replaced the power unit
Early in 2000 it started to stall again. I noticed oil running down the side of the motor. After 9 weeks at the dealer The fuel pump and rectifier were replaced at the cost to me $254
After the rebuilt fuel pump the motor started slowing down and I could get in back up to speed my pumping the bulb on the gas line. I lived with this till the end of the season but when it continued the next year I took the fuel pump out and found that they had put the diaphragm in backwards. Correcting this didn't solve the problem. I purchased a new fuel and the problem went away. Don't know what the dealer did to screw up the original fuel pump
I also had to replace the water power twice and I am currently waiting for a repair kit to fix the fuel pump again.
I also replaced the stator and a power pack again recently. I can't find my notes for the date of these replacements but I think by now you get the idea. I realize water pumps and fuel pumps have to be replaced but this motor is seldom used because it is on a sailboat and only turned on to get out and into my slip. When it runs its a great motor but I am a fraid to take long trips because I never know when the power pack will blow again. I bet in the 12 years I have had this motor it probably hasn't run more than most motors run in a year or two

 

[JB]

Re: Evinrude 9.9HP 4 stroke

Hmmmmm. Repeated failures blamed on the power pak, repeated fuel pump failures.

Water pump impellers need replacement each 2 years regardless of usage. Time is what makes them brittle, not usage. Same with rubber parts in fuel pumps.

I think I overhauled my fuel pump and carb and replaced my impeller each 2 years as preventive maintenence. I have no ideas about the power pak except that silicon semiconductor junctions are too #$%^&* temperature sensitive to put in an outboard in the first place. Unfortunately, I know of no easy conversion to reliable magneto ignition.

 

[Rudi2]

Re: Evinrude 9.9HP 4 stroke

Wow! I think your first problem was you bought a 4 stroke ! Seriously though, the OMC 2 strokes are some of the best outboards ever made, Why use anything else? I have a 1996 9.9 2 stroke that has never let me down in 13 years.

 

[roehrle09]

Re: Evinrude 9.9HP 4 stroke

Thanks,,,Now you tell me
Actual I still have a 7.5HP evinrude that I used when the 9.9 was in the shop. When the warrener ran out I started working on the motor myself because I couldn't afford the prices the shop was charging..... $254 to rebuilt a fuel pump.

 

[bankerjohn]

Re: Evinrude 9.9HP 4 stroke

Did the dealer ever say why the power packs failed? I'm currently having some issues with my 1996 motor ... runs fine up to about 1/2 WOT, but above that it seems to bog down and not accelerate.

I've replaced the plugs, wires and coil ... no improvement. I'm now wondering if the power pack is failing, but at $250 or more, I'm not inclined to replace it unless I'm 100% sure it will cure my problem!

 

[roehrle09]

Re: Evinrude 9.9HP 4 stroke

I'm not positive but I believe when the power pack goes it doesn't go half way. You just don't get a spark to the plugs. At least that is what happen to me. There is a off brand power pack selling for $64.36. It has the same part number as units selling at 2 & 3 times that price. Don't know why it is so much cheaper, maybe the higher price is just for the original OMC part. To replace the unit isn't an easy job. You need a wheel puller to get the Mag wheel off. I did it while the boat was on a mooring so it might be easier on land.
Here is the link for a cheaper unit.
http://www.prestostore.com/catalog.php/pmcparts/pd47064

Evinrude-Johnson Power Pack - 18-5767

Evinrude-Johnson Power Pack - 18-5767. Please use the PARTS CHARTS button (top of any page) to locate the correct part for your application.

$ 64.36 Back

 

[roehrle09]

Re: Evinrude 9.9HP 4 stroke

Another thing you might try John is some Seafoam shot into the Carb and also add 1 oz /gal to the tank. Sounds like the intermidiate jet maybe dirty and the Seafoam may help clean it.

 

[roehrle09]

Re: Evinrude 9.9HP 4 stroke

Hmmmmm.

I think I overhauled my fuel pump and carb and replaced my impeller each 2 years as preventive maintenence. .

When you overhauled your fuel pump do you remember seeing the small springs from the check valve come out of their holes. Today when I opened the filter top section of the assembly there were 2 very small springs and some other small parts loose that I believe were part of the check valve. I decided to buy a new fuel pump because I'm not sure how to assemble these parts. I tried looking for exploded views of the pump on the net. They aren't in my Evinrude service manual that I paid $35 back in 1997. It doesn't even have the part number of parts like the water & fuel pumps. I had to find these on the internet. I believe that these small parts may have ruptured the diaphragm The circular disks that are on both sides of the diaphragm, one had scratches on it and the other didn't. They may also have caused the tear in the diaphragm. I decided it buy a new fuel pump since I don't recall having to mess with these two small springs.
Just found my old fuel pump and the springs did NOT come out of their proper location. Apparently something "blew" them out because they are normally locked inside the check valve. Any idea what would have caused this ??

 

[JB]

Re: Evinrude 9.9HP 4 stroke

I don't remember how I knew, but I expected those tiny check valve springs to be where they were. Maybe my manual had exploded views, maybe I had just worked on so many different fuel pumps I was not surprised.

 

[roehrle09]

Re: Evinrude 9.9HP 4 stroke

Don't know if you saw I modified my last remarks. I found my old fuel pump and took it apart and the springs did NOT pop out and were locked inside their chamber. It is impossible to see them unless you pop the retaining clips. So some thing Blew them out on my unit. I don't know if they can be reinstalled but I don't think it is worth the effort to find out.

 

[roehrle09]

Re: Evinrude 9.9HP 4 stroke

Just a follow up. I was able to figure out how to get the 6 pieces that make up the check valve system. I am reluctant to use the pump again because I am not sure what caused the parts to come loose and it might happen again