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I am in the process of cleaning everything on the engine and winterizing my 1994 21 Outrage. I have replaced all the floats and gaskets in the carb. The engine is a 94 Evinrude 200. I Also removed the throttle body and cleaned and replaced all the gaskets too. My boat always had a hard time starting using the choke. I replaced the valve and gaskets on the choke solenoid. I also checked ohm and gave it 12 volts to see how the solenoid works. It all checks out. Does anyone know if you are suppose to receive 12 volts on the purple wire with the key pushed in and not turned? Or do u need to push and turned the key in to receive 12 volts? Sometime i hear a beep and sometimes i don't hear a beep when i turn the key. If i manually turn the valve, boat starts no problem. This is Driving me crazy. She started to spit and cough and dies toward the end of the season during idle so i decided to rebuild all the carbs. Strange thing is if you raised the idle via throttle, she is fine, she goes up to 40mph without a hicup. Checked the compression on all the cylinders and they were all between 114-110.
It's funny but you are having the same issues as me. I have a 2006 75hp etec. The only thing I have been able to come up with so far in terms of sputtering is possibly fuel pump related. A lot of the problems with this motor is in relationship to the ethanol inf uel. Also the kiss of death for a lot of them, but you im sure you know that.
Mine right now idles rough and can stall out. 0-6mph is hairy fluctuating in speed of about 2 mph. Feels like its going in and out of gear. I put roughly 120 hrs in it this season so need a tune up.
In regards to the choke, I believe the key needs to be turned for the choke to work (get power).
One of my good friends is thankfully an Evinrude mechanic. He's going to give me a hand diagnosing her. I'll let you know what I find out.
Thanks Joe, you are A life saver with that diagram. Now i have something to work with. After rebuilding the carbs, i decided to take the throttle body off and clean them too. i ran different gauge guitar strings thru all the small passages in the carb and throttle body and then blew everything out with air compressor yesterday. i ran her with the muffs on, no sneezing or coughing at idle. Only thing left to do is to sea test it again with the motor in the water. with the muffs on idle is about 800rpm, motor in water, she should idle at 600-650rpm i believe.
