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After a long winter indoors, many two-stroke outboards are reluctant to start. Simple maintenance should make your service more reliable. Steve Dawkins from Bursledon Outboards shows PBO’s Ben Meekins how it’s done.
EU rules mean you can no longer buy new small two-stroke outboards in Europe, but their light weight, compact size and long life mean they can still be found on boats from Caithness to Crete. Thousands of used examples available.
Early in the season, unreliability issues are most likely to arise, and for good reason.
“Most people think you can take the outboard engine off the boat and put it straight in the shed for the winter,” technician Steve Dawkins tells me in his workshop at Hamble River Cottage boatyard. “Then, in the spring, they are surprised when it doesn’t work.”
I was silent. My outboard has been sitting alone in the garage, surrounded by a bunch of ropes, fenders and sails, since it came ashore late last summer.
This step-by-step guide will help you perform maintenance on your small 2-stroke outboard. Photos show Mariner 3.3 hp outboards. and Suzuki 2 HP, and although the engines of other brands are slightly different, the main components should be identified.
Anyone with some technical ability can perform this service easily, but if you have any questions, please contact your dealer. If you’re going to do this yourself (mostly for late model engines), first make sure what you’re doing won’t void your warranty.
“The most common complaint we get is people saying everything worked fine last year but now it won’t start,” Steve said. This is because gasoline evaporates over time, leaving behind an oily, waxy residue that causes the carburetor to jam. So, the first thing you need to do is drain the old fuel.
3: If necessary, remove the water tank and remove any residue or debris. There is usually a small filter above the fuel valve.
Remove the spark plug along with its socket. The electrodes of a working plug should be brown or gray. If not, remove the carbon deposits and check that the spark gap is within the engine manufacturer’s recommendations. If the ceramic insulator is damaged or the electrodes are burnt, you will need a new plug.
The recoil starter is secured with three bolts. Remove them and turn the starter over. Check the cable for wear and spray lubricant on the springs and bearings.
The carburetor is located at the front of the engine and is responsible for ensuring proper mixing of fuel and air in a two-stroke engine. A clogged carburetor means the engine is running rough and won’t idle properly. The solution is to remove, remove and clean the carburetor.
1. Loosen the clamp and release the carburetor from the mounting base. Make sure the O-ring is not missing.
3. Place the bowl in a container of carburetor cleaner, use a small wire brush to remove any corrosion and residue, and allow it to soak for a few hours.
4: Then remove the float. The height of the float is important, so it’s a good idea to take a photo of the valve at this point so you can put it back together exactly as you found it.
5: Push out the needle valve pivot pin and remove the float arm. On some engines, the needle valve is connected to the float, so you may have to remove the pin in front of the float.
6: Then remove the main nozzle. Unscrew it, make sure the hole (insert) is clean, and to be sure, wet it with carburetor cleaner. “Nine out of ten problems we find are caused by a clogged main jet,” Steve said.
8: Reinstall it on the engine. Make sure the O-ring is installed correctly, otherwise you will have serious problems later.
1. Remove the transmission to inspect the water pump. On multi-gear engines, the pump is located on top of the transmission assembly, so if your engine has gears, you will need to loosen the gear linkage first. On smaller engines the pump impeller is located behind the propeller (see below). 27
1: Remove the round plug usually located above the gearbox. Move the shift lever until you can see the connecting rod nut and loosen it with a wrench.
2: Now remove the gearbox by loosening the bolts holding the gearbox in place and carefully lift it out of the downtube.
3: Loosen the bolt and slide it up along the drive shaft to remove the pump housing. Be careful not to lose the keyway (see 6).
7. Reinstall the pump housing and impeller. After sliding it all the way, turn the shaft so that the impeller fits correctly.
8: Now install the gearbox on the down tube. Carefully push the transmission into place, making sure that the water hose (small fitting above the transmission link in the picture) is free and properly positioned in its socket.
Remove the propeller and then the plate behind it. Behind this plate is the water pump impeller.
A professional will perform a pressure test to ensure the seal is still working properly. This is difficult to do without the right equipment, so a visual inspection will have to be done. One way to determine if there is a serious problem is to place the engine on a clean piece of cardboard overnight and check for obvious leaks in the morning.
Check to see if water has gotten into the oil. If the oil is blue or clear, everything is fine, but if it is cloudy or has sediment, there may be a problem. To determine this, you can use an oil test kit. If there is a leak, take it to your dealer to have the seal replaced.
Fill the transmission with new oil from the bottom up – most of the transmission oil goes into the squeeze tube or pump tank. It is full when oil starts flowing out of the top hole.
The anode is usually located above or below the cavitation plate. It is important to replace the anode before it reaches the stage shown in this photo. Be sure to replace the salt/fresh water with the correct type.
4. Remove the propeller and inspect the safety pin – remove, lubricate and replace. Remove the line from the propeller shaft, lubricate the shaft and reinstall the propeller.
Now, with the lid closed, place the outboard in the fresh water tank, make sure it is running properly, and then finally lubricate all the moving parts, especially the clamp screws and throttle valve.
1 Salt water is your engine’s worst enemy, so you should rinse your engine with fresh water after every use, otherwise the engine will begin to corrode from the inside.
3 Before stopping the engine, turn the fuel switch off while the engine is running and allow the fuel to drain: This will clean the fuel line and carburetor and prevent oil deposits from forming in the carburetor.
4 Check if there are spare pins. Place tape on the inside of the hood so you know where to find them when you need them.
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Post time: Oct-26-2023