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1993 EvinRude 115 hp Nightmare

H

HNeely22

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We have had issues with our 115hp since the day we bought our fixer upper pontoon from some friends. When purchased it didn't have reverse which we knew. So we ordered a used lower unit and put it on. After a weekend on the water the foot locked up and we were left having to be towed in. Gears were gone in that foot out of nowhere. My husband and I ordered yet another used foot (at that point we would have done better financially to have just bought new from the beginning). Put new lower unit on everything was done by the manual. Started having some issues with the solenoid/starter. After turning the key off the solenoid would keep trying to crank and we'd have to tap on it to get it to stop. Got a new solenoid, replaced it and the issue kept happening so we ordered a new starter and while it happened less frequently it still happened. Eventually bypassed the safety neutral switch in the wiring and that fixed the issue somehow. Fast forward to last weekend we cranked the boat at home before we drove to the lake. Cranked up right away. Backed the boat into the water and cranked it again and then died. Which isn't unusual for the first crank in the water. After that I tried to crank it again and it did absolutely nothing. Wouldn't even try to turn over. Seemed like a dead battery. We have an extra battery so switched it and still nothing. My husband wasn't with me so we just left and went home. Once my husband got home he realized the starter gear was completely jammed into the flywheel. Where it's supposed to be tooth to groove in the gears it was tooth to tooth. He got the started gear free from the flywheel and we cranked the boat right up after that. It was idling about 800 RPMs higher than usual so my husband adjusted the idle. I putthe the boat in forward and reverse several times just to make sure everything was working correctly. It was shifting smoothly. The third time I put it in reverse there was some clanking (think wrench in gears clanking) and suddenly the motor stopped. Checked the started and fly wheel. All looked fine. I just knew it was in the lower unit. I removed the drain plug for the gear lube and what started out at 30+ oz of gear lube pours out only about 3/4 of a cups worth. Also it was very stinky (rotten eggs) andalmost green in color. Thick cloudy green. There were metal shavings stuck to the drain plug and a larger (pea size) piece of metal came out at the end. The propeller is locked up in neutral so we are assuming the idler gear (?) is the one that got eaten up. We are just at a loss as to why this would have happened and if we even want to continue in the boating world after we have had SO many issues in just few short months. Does anyone with more marine engine knowledge have any insight on why we would have gone through two lower units in such a short amount of time?
 
Working with a manual ?-------------Those lower units are actually very good and reliable.------Maybe have a look at the original for an easy fix.-----And there is no " idler gear " in those lower units.
 
racerone said:
Working with a manual ?-------------Those lower units are actually very good and reliable.------Maybe have a look at the original for an easy fix.-----And there is no " idler gear " in those lower units.
Click to expand...

Thank you. The idler gear part was just the suggestion my dad had. He's an automotive mechanic definitely not a marine mechanic. Yes we are absolutely working with the manual and have been all along. I purchased on as soon as we purchased the boat. The original needs a reverse gear. My father and husband are a bit more knowledgeable about these things than I am. Was just wanting to get some insight on a few things. This is the 3rd lower unit that we have had a gear go out in so I'm getting a little frustrated at this point.
 
racerone said:
Working with a manual ?-------------Those lower units are actually very good and reliable.------Maybe have a look at the original for an easy fix.-----And there is no " idler gear " in those lower units.
Click to expand...

I believe it's pinion gear instead of idler gear.
 
I wish that was all it was however it was the gear. But I'm hoping it is just reverse gear that's bad in it and we can replace it. We didn't want to mess with that originally but at this point I think it's the best option.
 
HNeely22 said:
When purchased it didn't have reverse. We ordered a used lower unit and put it on. A weekend on the water the foot locked up. We ordered and installed another used lower unit by the manual.

Started having issues with the starter solenoid. After turning the key off, the starter would keep cranking and we'd have to tap the solenoid to get it to stop. Installed a new solenoid but the issue continued. We ordered a new starter and it happened less frequently. Eventually bypassed the safety neutral switch in the wiring and that fixed the issue somehow.

Last weekend we cranked the boat at home, okay. At lake, backed the boat into the water and cranked it again and then it died. I tried to crank it again and nothing. Wouldn't even try to turn over, like a dead battery. We have an extra battery so switched it and still nothing. My husband realized the starter gear was jammed up under the flywheel tooth to tooth. He freed it and the engine cranked up after that.

I put the the engine in forward and reverse several times just to make sure everything was working correctly. It shifted smoothly. The third time I put it in reverse there was some clanking and the motor stopped. I just knew it was in the lower unit. I removed the drain plug and what started out at 30+ oz of gear lube pours out only about 3/4 of a cup. It was stinky and almost green in color. Metal shavings stuck to the drain plug and a larger piece of metal came out at the end. The propeller is locked up so we are assuming the idler gear is the one that got eaten up.

We are just at a loss as to why this happened and if we even want to continue in the boating world after having so many issues in just few short months. Does anyone with more marine engine knowledge have any insight on why we would have gone through two lower units in such a short amount of time?
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NOTE: When there is a lot that needs to be typed, it makes for easier viewing if one breaks it up into short paragraphs.

The safety neutral switch has nothing to do with a sticking starter solenoid... that cure was simply a coincidence. A sticking starter solenoid is caused by either a undercharged battery, a bad battery, or cables associated with the starter circuit that are either loose or tight BUT dirty (Low Voltage). I'd suggest you remove, clean, and re-tighten all cables/wiring and the components they're attached to that are associated with the starter circuit to avoid another sticking solenoid scenario. This includes the actual battery terminals and the main ground cable at the power-head.

Mechanical shift engines require 90w "HiVis" gearlube. Hopefully this is what you used.

When purchasing used gearcases, keep in mind that normally the seller really has no idea what is within those gearcases UNLESS he has dismantled them completely and restored them to like new condition. They may be in perfect condition, and then again... they may be be just moments from exploding, as you have discovered.

For you to fill the gearcase, only to have just a cup of gearcase lube remaining a short time later, at least one seal had to be in very bad condition.

When purchasing a used gearcase... and it's a used one, not one reworked by the seller... it is up to you to tear it down for inspection and to reseal it before installing it to insure that a failure isn't just a few moments away.

I wish you luck with your future boating endeavors.... It normally gets better. :)
 
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