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Tohatsu 9.8 choke solenoid

cflowers

New member
My Tohatsu 9.8 has not been starting well, if it starts at all. It has a remote control in which pushing the key in activates the choke. Looking at the engine, the choke solenoid plunger moves very little (a quarter inch) when I push in the key. After various other steps in the diagnostic process, I was finally able to get the engine to cough and even sputter. After noticing the choke plunger barely moving, I manually pushed the choke closed (as per the manual). You can flip into the closed position and it "locks" there. The engine started fine, and kept going, with the choke fully activated. I don't know how far the plunger should be moving when you push the key in. I'm thinking the plunger is not moving far enough and therefore the choke solenoid is bad. Am I on the right track? What else could it be?

Thank you!

-cf
Craig
Champaign, Illinois
 
This was solved. The choke solenoid is fine. I read in the service manual it doesn't have to move very much to provide the necessary choke.

The problem was convoluted. I had cleaned the carb and installed a carb rebuild kit over the winter. (Why? I couldn't get it to start at the end of last season. We had a heat wave and I was using ethanol fuel and hadn't used the engine in 6 weeks.) Upon re-installing the carb, the gasket slipped and I completely missed the hole. So it was difficultly to start. I had to over-choke it. (Does that make sense?) Then it would rev up and down on its own and die if I put the remote control in idle. (The boat is on the hard BTW.) I fixed other issues I had created (see my post about the impeller) and was left with a motor that would not run reliably.

Researching this forum, I learned from other posts that I might have an air leak or the carb was not totally cleaned (I did not do a full dip; just used a carb cleaning spray.) Distraught, I returned to the boat today to remove the carb to re-clean it properly. That's when I saw the misplaced gasket. I reset the gasket (Of course, it tore so I pieced it back together and ordered a new one.) and fired it up.

Turned over on the second try and after 30 seconds it ran like a top. At idle it purrs like a kitten and pees like a racehorse.

Many thanks to the people in this forum especially Paul (pvanv). His answers to other people's issues helped me to understand what I was dealing with. FWIW, I asked AI too but didn't learn anything I hadn't seen here first. YOU CAN fix your own engine.

Just to close this off, the whole affair started a year ago when I cleaned the gas tank and filled it with unleaded containing ethonol. The new marina gas dock was closed that particular week so I figured, "What can go wrong?"

Crazy eh? I hope this puts a smile on someone's face.

Craig Flowers
S/V April Fool
Clinton Lake, Illinois
 
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