Recently purchased a jon boat with a 1996 25 hp electric start. Well one of the bolts broke off that holds the starter in place, so it will no longer engage the fly wheel. Tried to remove it with a screw extractor and proceeded to break that off in the bolt so I am now double screwed!! Any ideas on how to get this out? I am not looking to spend a bunch of money on the fix.
On another note the motor will sneeze and cut off when in idle if not kept at higher RPMs. Changed the plugs and it didn’t help. Any ideas as to what is causing this? Maybe a clogged up carb?
You are kinda screwed on the broken extractor. Those things are hard as hell and usually cobalt bits wont touch them. Heat will not do any good either. When this happens, I use micro burrs and carefully cut around the broken extractor to get it free. Then you can use the same burrs to cut the bolt in half and extract the pieces. If you are good, you will not mess up the threads. This is going to be fairly expensive as its time consuming.
The sneezing is from leaning out. You probably have a plugged hole in an idle circuit in a carb. They are the smallest and easiest to plug up. The best bet would be to disassemble the carbs and clean/sync up.
Thanks Matt I do not have the tools or experience for the job. May just take it to a shop and see if they can drill it out and re-tap it.
I am thinking of just buying a carb rebuild kit and doing it myself. Do you know if the carb rebuild kits come with instructions? Or is that going to be found in the manual? Which I do not have!!
YouTube will be your best friend. Plenty of videos of cleaning carbs. Take your time, and have a clean environment to lay everything out. You need a can of carb cleaner and an air compressor. Try just cleaning the carbs first without rebuilding.
Thanks Palmer I am going to try and remove the carb today. If I screw it up I will just take it into the shop…if this motor keeps acting up keep an eye out in the classified for a great deal on a boat! Islander its a 1996 evinrude electric start.
Does the motor have a pull cord? If you get the motor running smoothly that engine should be easy to pull start. Then you wouldn’t have to worry about your battery either.
Islander its a 1996 evinrude electric start.