Only runs with choke engaged - Evinrude 4hp BE4BREIA

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Diamond-geezur

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Good morning all,

This is my first post and thank for your being such a nice place.

I would like to ask you to help resolve my headache.

I have a 4hp twin 2 stroke 1991 engine and it ran really good in summer, even got up on the plane.

I ran out of fuel whilst running and it then would not start or if it did, only run on choke.

I have done the following:

New fuel filter
Fresh fuel
Carb rebuild with kit
New spark plugs
Compression test (do not know correct compression but but cylinders were equal at around 110 each)

I rebuilt and cleaned the carb 4 times yesterday and even tried using fishing line to clean jets etc. This was my first time rebuilding a carb but learnt a lot.

What am I getting wrong? I can start the engine with choke engaged and run it through the revs, engage gear etc. As soon as I take off choke it cuts out.

I've had two 'older' engine blokes look at it, one did the first carb rebuild for me and other did compression test but that's all the help I have. During compression test engine started on one pull and ran with one spark plug missing which is a good sign.

I've spent hours trying to research and fix it, I had the best time ever using it in the summer and just want it to run.

I would give anything to get it working. I have already spent too much on parts and should give up and but I am giving it one last shot..
 
The only other thing I can add is - the cover plate gasget. It has some oil leak but not much. Would this cause the issue?

As compression is good - it makes me think this engine is worth getting fixed. I just don't want to sell as spares and repairs as it ran so good during the summer.
 
If it's running fine on choke you are either leaking air somewhere, the pilot jet is blocked or float height incorrect
 
Thank you for the replies - is there any way of me finding the possible leaking air? I keep trying all different option and replaced many part but no luck. My engine does not have an air filter.

When I did the carb clean I was excited as some muck came out but still same issue.

With choke out o can start it first pull, do whole rev range and engage gear. So frustrating.

I'll check air filter and as for the jets I've tried to clean so many times and use seafoam in past too.

Any more help would be much appreciated. Thank you.
 
Last edited:
Does it occasionally stall or start to stall ? then recover if you open & close the throttle rapidly ? ................air filter.
 
Diamond-geezur said:
The float was recently changed during carb rebuild - could it be that I need to adjust?
Click to expand...

yes. Done at the tang that connects to the needle and seat. btw have you checked there is no guaze filter that is clogged above the needle and seat. Some small carbs will have this. Do you have a service manual? It should list the float height or you may need to find the carb manual from OEM.
 
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