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Starting Problem

PRanger

New member
I have a 2003 18hp Nissan, 4-Stroke Outboard. Up until this year I have had no problems with the motor. However, this year I had to replace the impeller and adjust the valve lash. The problem I'm having is on cold days (around or below freezing) it takes 10 to 15 pulls before the motor starts. Once the motor starts and warms up I have no problem restarting the engine or any other problems on the water. The motor has the 'Auto-By-Starter Ass'y and the only thing I can figure is this unit must be bad. I had the engine into a mechanic who took the carb off and apart and said there was nothing wrong with it. He claimed it started for him in 1 or 2 pulls (in a warm shop however).
Would replacing the 'Auto Choke' be the most likely resolution to the problem, or am I missing something here?
 
IF the low speed circuits in the carb are impeccably clear and clean (was the carb actually cleaned?), there is a possibility that the ABS solenoid is not working correctly. I would double and triple check that the carb is very clean. At low temps, more enrichment is needed, and that will be impossible if there is even a hint of varnishing in the low speed passages. Do you run the carb dry at the end of each and every day? If not, have the carb cleaned in a proper carb dip bath, and then try it again. Before buying a new ABS, I would test it. They aren't cheap. Apply 12v to the leads, and over the course of a couple of minutes, the pin should move measurably. If not, then it's time to replace it. 3R3034100M AUTO-BY-STARTER ASSY $144.58 is available from any dealer, including me.
 
Paul,

Thanks for the reply. Yeah originally I took the motor to the same mechanic 3 times because it would die after trolling for a long period of time. I would throttle up from idle and it would simply cut out. Then it was really hard to get started again. The plugs were also fouling real bad, and this mechanic coudn't seem to fix the problem, however he did say he cleaned the carb. I than took it to another mechanic and he suggested adjusting the valves (which he did). This eliminated the fouling plugs, but then I noticed the water pump wasn't putting out much water. So I changed the impeller.
All the time however it's taken several pulls to start the motor. I went out this morning (fishing) and it took about 12-15 pulls before it started. It doesn't miss a beat once it's started nor does it cut out anymore however. I should probably mention that I fish Lake Tahoe which is at about 6200'.
Do I have to take the Auto Choke Assy. off the carb to be able to see the 'pin' move? And you said hook it up to 12V leads - right?
I used to run the carb dry but one of the mechanics said it really didn't matter whether I did or not? I always thought it was better not to leave any gas in the carb to create varnish. Your thoughts?

PRanger
Thanks for all your help. I can't seem to find a decent mechanic around here that either knows anything about Nissan's or really gives a S__.
 
It sounds like you have both too-lean and too-rich conditions, depending on throttle. At 6200 feet, you should be running high-altitude jetting, to avoid drowning the plugs in fuel. That contributes to the premature sooting, but the high-altitude jetting will be too lean at sea level, so you would need to change back to standard jetting for use at low altitudes. If your dealer is unfamiliar with those jets, they can call Alan or Tommy at Tohatsu America for details. If your dealer gives you a glazed-eye look when you mention high altitude jets, drop me an email: [email protected], and I'll be happy to help you.

If you are having problems tipping-in (coming off idle to power), the accelerator pump is probably not delivering enough extra fuel to avoid the stumble, and the slow or midrange circuits may not be clean enough. When going through these carbs, it's important to remove the tiny screw that retains the accelerator pump plunger and spring, and make sure those passages are clean as well. Then test the plunger. It should operate freely, with little or no resistance. If the pump bore in the carb bowl has Any oxidation, change out the bowl. The best way to clean these carbs is a careful and complete disassembly, a 4-hour bath in real carb dip, a blow-out with generic carb spray, and then a careful reassembly and adjustment, paying particular attention to float height.

Yes, it is critical to run the carb dry at the end of each and every day, unless you can guarantee that you will be running again tomorrow. Today's US fuels are not nearly as clean and stable as they were years ago, and they leave varnish deposits as they evaporate out of the carb. This is especially problematic in the newer carbs of the 4-stroke motors, which have longer, narrower passages (which are necessary in order to produce very emulsified mixtures of air and fuel to meet EPA emissions guidelines). I would also recommend a water-separating fuel filter, to help pre-filtering the fuel, and keep water contamination to a minimum. Likewise, if your fuel gets to be over 30 days old, dump it in the car's tank to get rid of it, and run fresh fuel.

In order to check the ABS solenoid, you remove the single retaining screw with a #2 phillips driver, and then pull the solenoid up out of the carb. The solenoid has 2 wires (polarity does not matter) that operate a heater; that in turn causes expansion of a chamber, which causes the brass pin to move. They can fail, but rarely.

BTW, when servicing the water pump, always install a complete kit (includes the wear plate and cup as well as the impeller) to get more life from the pump. Same labor, a few more dollars, and a lot longer pump life.

If you are having problems locating a servicing dealer, you can look them up at http://www.nissanmarine.com/search/index.html. The 9.9/15/18 units of your vintage are the same motor in Tohatsu, Nissan, and Mercury , so even a Merc dealer should be able to help you. OTOH, if you want to tackle the work yourself, start with a Factory service manual (forget the aftermarket manuals), and review it before beginning work.
 
Paul,

I appreciate all your expertise regarding my questions. Here is where it stands after a few checks/tests.

I pulled the plugs and they both look fine (tan in color). However, I would like to order the high altitude jets. What does the kit contain (just the main jet); or is it the main nozzle and slow jet too? Could I order them from you? Do you just pull off the lower bowl to install or is it harder then that? If it's not much harder then the impeller install I could probably figure it out. I did install the entire kit and I do have the Tohatsu Service Manual.

As to the ABS. I disconnected the leads and took it out of the carb. I then hooked it up to a 12V battery and got NO movement of the pin at all. I thought I'd try putting it back on the carb WITHOUT plugging the leads back in - and try starting it. It started EXACTLY the same without it plugged in as it did yesterday morning - about 15 pulls. I was surprised it started at all! The ABS was warm to the touch but it doesn't appear to be working. Would you assume ( you probably hate that word) that the ABS is shot? If so, could I also order this from you? I got a price of around $140 from NissanOutboardParts.com but since you've been so helpful I'd rather give you the business.

Again I appreciate your help.

PRanger
 
The HA jet kit includes both the main and slow jets. You re-use the same emulsion tube nozzle. To install the jets, you remove the bowl, and then remove the rubber plug that covers the slow jet... Then unscrew and replace both jets... then reassemble. You must replace the rubber plug, or the carb will draw way too much fuel.

If you apply power to the ABS and it does not move, even though it heats, (assuming you are at normal room temperature or below) that indicates that while the heater is working, the expansion module isn't working. In that case, yes, you found the cold start problem (by methodical testing instead of guessing!), and need a new ABS solenoid.

I'd be happy to help you with parts. I'm in the office MWF, 9-6 Eastern this time of year. You can call 716-877-8221 or just drop an email.
 
IF the low speed circuits in the carb are impeccably clear and clean (was the carb actually cleaned?), there is a possibility that the ABS solenoid is not working correctly. I would double and triple check that the carb is very clean. At low temps, more enrichment is needed, and that will be impossible if there is even a hint of varnishing in the low speed passages. Do you run the carb dry at the end of each and every day? If not, have the carb cleaned in a proper carb dip bath, and then try it again. Before buying a new ABS, I would test it. They aren't cheap. Apply 12v to the leads, and over the course of a couple of minutes, the pin should move measurably. If not, then it's time to replace it. 3R3034100M AUTO-BY-STARTER ASSY $144.58 is available from any dealer, including me.
Do you sell this part 3R3034100M AUTO-BY-STARTER ASSY?
 
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