posted 07-20-2008 09:25 AM ET (US)        

--I now use 92 octane gas

--I allow the motor to warm up prior to putting into gear

--I have replaced transfer gear switch in the motor, the small switch in the motor the changes from forward to reverse; this helped it from stalling when I place the motor into reverse.

However, after doing all this it still stalls out [when shifted] into forward. Any suggestions or help would be appreciated. What can it be?

posted 07-20-2008 11:02 AM ET (US)            

I suggest you:

--check your idle speed setting, as it may be set too low;

--check your carburetor throttle plate linkage and engine timing advance, a procedure known as "sync and link;"

--check that the throttle cam roller is intact. If the roller is missing it can upset the throttle linkage synchronization.

See item 12 in the illustration linked below:

posted 08-30-2008 04:32 AM ET (US)            

However, yesterday while fishing a need problem developed:

After re-starting on a warm start the motor would cut out after a minute or so – almost the same problem I had. Tried re-starting it several times and it would start and then cut on once I try putting it in gear. After the third and fourth re-start the motor cut out and lost all power to the motor - trim was not working, ignition not working etc... Checked all fuses (OK) - all electronics and boat power were fine (they were all using the same battery as the motor) - checked main cut-off switch (OK) - turned the cut-off switch on and off, touched the trim on the motor and the power came back on the motor. Re-started the motor and allowed it to warm up longer and increased RPM's in neutral – this seemed to work. After, running full out and slowing down the engine chimes and warning lights (sound and lights you get once you turn on the motor) came on – However, no warning light stayed on.

Any suggestion???

posted 09-02-2008 12:29 PM ET (US)            

I don't think the 2002's have fixed-jet carbs, but I'll give you my experience with an '87 225 Evinrude that had the exact same issue. It was EXTREMELY frustrating to be stuck at idle speed in the Gulf of Mexico. I went through 3 mechanics until I found one who solved the problem (Acie of Acie's Outboards in Kemah, TX--GREAT OMC/BRP service). Acie attributed the problem to "heat soak." It's been a few years, but I'll try to paraphrase the best I can. Please understand that this is from memory of what I was told.

In my case, the heat soak issue case reared itself in the transition from the low-speed jets to the high-speed jets. In the old, fixed-jet V-6s, Acie explained to me that when hot, especially in humid conditions, the motors sometimes died on the transition due to minute traces of water vapor that formed droplets on the jets. According to Acie, ethanol fuel added to the problem, contributing more water vapor, and those droplets interfered with the flow of fuel from the high-speed jets during transition. The cure was to try a larger set of high-speed jets (but not too large, or it would run too rich).