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nunk

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Reply with quote  #1 
I recently acquired a used boat with a 2010 75 E-TEC motor, Model No: E75DPLISD & S/N: 05264664.  On the first outing, when I pulled back on the WOT lever, the motor remained stuck at full throttle.  Only some quick thinking on my part averted a rather nasty incident.
Upon return home, I carefully inspected all the relevant components.  I found that the Throttle Cam (5005186) was operating freely with no binding. as was the Throttle Lever (5005187) which was freely returning by means of its return spring.
Removing the Link Arm (5005626) from the Throttle Shaft Lever Assembly (5005188) I was then able by hand to rotate this Assembly to fully open the butterflies and found that they would not return in spite of the torsion spring at the base of the shaft being fully loaded.  A little help from me to start the return allowed the bottom spring to do its job and return the butterflies to closed.  It appears that the butterflies shaft is binding at WOT, apparently in its nylon? bushes. No amount of CRC or WD-40 has improved the situation so I have now added an auxiliary tension spring between the Throttle Shaft Lever Assembly and an available lug on the Intake Manifold casting.  This has solved the problem and throttle sticking is now no longer experienced.
However, I'm concerned about the operation of the Throttle Shaft Lever Assembly atop the butterflies shaft.  From a fully retracted (clockwise viewed from above) position, I find that there is about 30 degrees of free anticlockwise rotational movement BEFORE it engages with the butterflies shaft and begins to open them.
My question is:  Is this normal, or is it indicative of serious wear in which case it (5005188) needs to be replaced??  This part is common to all horsepower versions from 2004 on so hopefully there must be some experience on this forum.
PhilH12

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Reply with quote  #2 
I thought that Oly said it might be time for a new 'throttle body' on your original post.  Need to keep those 'tolerances' on the shafts, etc. a bit closer to 'normal'.


[It sounds like you need a new throttle body. 
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Phil



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Always check the Easy Stuff First!
20' Weeres fishing pontoon
90 HP E-Tec E90DPLSUM  05184332
Lake Tawakoni, TX - Catfish Capital of Texas
seahorse

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Reply with quote  #3 
Any signs of salt spray on the powerhead or ingestion through the air silencer?
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nunk

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Reply with quote  #4 
Yes Phil, it is a repeat post.  Based on Oly's advice, I've now moved it to the appropriate section.

Could you possibly expand a little on just what you mean by "Need to keep those 'tolerances' on the shafts, etc. a bit closer to 'normal'?

What are the 'tolerances' and what is 'normal'?

By 'throttle body', are you referring to part no 5005188 described in the parts list as Throttle Shaft Lever Assembly?

Thanks, Neil
nunk

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Reply with quote  #5 
No signs of salt spray on the powerhead or ingestion through the air silencer.  All completely free of foreign material.
PhilH12

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Reply with quote  #6 
Sorry, but I'm No expert on your motor for 'tolerances' or 'normal'.  Addressing your question - [I find that there is about 30 degrees of free anticlockwise rotational movement BEFORE it engages with the butterflies shaft]

As a metal shaft turns in a hole, the hole and shaft can wear, as does any other moving parts rubbing together.  This all produces 'slop' or 'play' that you are seeing when you can turn as much as you say before 'movement' occurs.  I believe (and may be corrected) that this is what Oly was saying.  You can't just buy a replacement part or two - might be time for a new assembly.

Hope it helps!  Experts such as Oly will chime in again, with their years of making a living servicing these.

Phil

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Always check the Easy Stuff First!
20' Weeres fishing pontoon
90 HP E-Tec E90DPLSUM  05184332
Lake Tawakoni, TX - Catfish Capital of Texas
nunk

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Reply with quote  #7 
Thanks Phil.  
I notice from your posting that you have a 90 HP E-Tec E90DPLSUM.  That is a 2007 model and will have the same part that I am questioning the operation of.docx 5005188 - Throttle Shaft Lever assembly.docx     

So could you possibly check the amount of free rotational movement of this part on your motor and advise?  That is, between the fully retracted position to the point when it starts to open the butterflies.

I can well envisage the engaging end of the butterfly shaft 'flogging out' the moulded base of the plastic 5005188.  If it weren't for the fact that the TPS is held in position with 'push nuts' (more like washers), I'd have had it off for inspection.  I will probably do that anyway but I was hoping to learn from the experience of other owners beforehand.
 
Many thanks,
Neil

PhilH12

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Reply with quote  #8 
I'll definitely check it, but I like to do "as little as possible" over the water.  The boat lives in a slip.  I'm about to pull it for a couple other things anyway, so I can let you know, but it won't be "immediately".

Phil

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Always check the Easy Stuff First!
20' Weeres fishing pontoon
90 HP E-Tec E90DPLSUM  05184332
Lake Tawakoni, TX - Catfish Capital of Texas
olypopper

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Reply with quote  #9 
You are correct in thinking your throttle lever moves quite a ways before the throttle plates open. This is normal and how they are designed. The sticking is NOT normal and you should likely replace the throttle body.
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nunk

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Reply with quote  #10 
Thanks Phil,
In light of Oly's response, it would be great to have this confirmed.
Thanks Oly,
Giving some more thought to the subject based on your advice, it would appear what I have observed is indeed quite normal. I found a picture of the underside of the 5005188 Throttle Lever and it shows two opposite segments of about 30 degrees into which the top of the butterflies shaft must mate..  The lever would need to turn through this angle before engaging the shaft.  The TPS above however is actuated over the whole rotational range of the Throttle Lever.
With respect to the WOT sticking problem, the attached pic shows the Auxilliary throttle return spring.JPG  Control lever 5005188 - bottom view.jpg  auxiliary return spring I've added.

PhilH12

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Reply with quote  #11 
Just to get back to you.  Not sure it answers your question, but I can push forward at the Gray plastic connector at the top of that arm (above the yellow/brown spinning bushing) about 3/8" to maybe 1/2" before it 'engages' the throttle plates.  I've been wrenching a few other "details" on mine, nothing much, but haven't checked your comparisons in depth.

As Oly says, the sticking on return isn't Normal though.  Might be corrosion or something around the shaft that causes the 'bind'.

Phil

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Always check the Easy Stuff First!
20' Weeres fishing pontoon
90 HP E-Tec E90DPLSUM  05184332
Lake Tawakoni, TX - Catfish Capital of Texas
seahorse

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Reply with quote  #12 
Is the spring at the bottom of the shaft still wound tightly and can you feel return pressure from it? You may have to remove and inspect the TPS and its plastic connectors for resistance.

The wire-like link from the throttle lever to TPS shows a lot of corrosion along its length. Are you in saltwater? 

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nunk

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Reply with quote  #13 
Thanks Phil,
You've confirmed my observations which indicates that this is the normal situation as stated by Oly.
Thanks Seahorse,
Yes, the bottom spring is tightly wound at WOT and return pressure is readily felt, once the butterflies are relieved from the WOT sticking position.  To fully dismantle and inspect the total TPS/throttle lever/shaft/spring assembly, I'd need to remove the Throttle Body Assembly (5006457) from the motor. I'm not keen to do this at this stage so the auxilliary spring will serve in the meantime.
The wire link 'corrosion' is in fact an accumulation of grease/oil/dirt which I have now cleaned off (I should have done that before taking the pic).  And yes, I run in salt water.

Neil

PhilH12

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Reply with quote  #14 
Not sure you can even get at 'em, but some spray lube/ parts blaster may free up the shaft a bit?  Do Not spray near the TPS though.  That's mentioned a couple of times in the Service Manual.

Phil

__________________
Always check the Easy Stuff First!
20' Weeres fishing pontoon
90 HP E-Tec E90DPLSUM  05184332
Lake Tawakoni, TX - Catfish Capital of Texas
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