How To Unclog An Outboard Motor

Q: Six years ago I purchased a new 25 hp 4-stroke carbureted Mercury outboard motor. The carb is now suffering the effects of ethanol—a clogged fuel port stalls the engine at mid-throttle. I understand there are additives that will prevent or minimize this in the future, but is there anything on the market that will clean the carb out without having to dismantle it?

A: The only one I know of that claims to use enzymes to dissolve the organics left behind by ethanol is Starbrite’s Startron.

I’ve tried some in a generator that was left to bake for two years without fuel stabilizer. Just adding Startron wouldn’t get it started, but disassembling the carb showed why—the main jet was totally plugged, and had to be reamed out.

Because your outboard is still running, the additive might make is way in and dissolve the gunk.

On the other hand, I’m reluctant to tell you to do this and then have you stranded miles off shore when the carb plugs up completely. Got a second outboard motor on board?

How Your Headlights Work

Headlights have come long way since the crude lamps that lit the way for the first cars. Modern headlights use deceptively interesting tech to produce your car's beams, and the next generation—based on lightweight, energy-efficient LEDs—are on the way.

I'm willing to bet that drivers only think about headlights during one of two events: when for some reason they can't see at night, or when an oncoming car blinds them. Like the alternator, these critical pieces are overlooked—until they don't work. And that's a shame, because for the gearhead, there's a lot of interesting tech behind the glass. Like, for example, did you know that an HID headlight is like a lightning bolt in that a glowing arc of electricity illuminates the fixture? Plus, automakers are calling on headlights to increase not only safety but also fuel efficiency.

Knowing how your lights work will better prepare you to keep them maintained, so you're more likely to see that deer before it runs into your path. Besides, the rapid evolution of headlight tech is interesting in itself. Here's a primer.

The Old-Fashioned Way

The first cars used crude lamps fueled by either kerosene or (gasp) acetylene. About 100 years ago, the open flames were replaced with a small electric bulb housed between a polished reflector and a lens. These lights weren't sealed well, so the reflector corroded quickly, making the already insufficient lights even dimmer—and worse, they provided plenty of glare to oncoming traffic. These types of lights were made illegal in 1941, a scant year after the introduction of the sealed beam.

Sealed Beams

A sealed-beam headlamp is nothing different from a giant household bulb, a tungsten filament housed in a glass enclosure that's sealed and filled with inert gases. The reflector is inside the glass envelope. Like household bulbs, these gradually lose brightness as the tungsten evaporates from the filament and deposits on the reflector. Dippable high-and-low beams didn't come along until the '20s. Brightness and beam control in this era were inconsistent because of poor manufacturing tolerances. And the inside of the poorly sealed glass lens easily corroded, further reducing the brightness. Sealed-beam lights were cheap partly because they came in only three sizes—5- and 7-inch round and one square size—but more important, the standardized sizes limited styling differences among cars. Automakers started replacing sealed-beam lights with quartz-iodine technology in 1973.

Quartz-Iodine

Sylvania Silverstar H13 1. Quartz Glass 2. Support Strut 3. High Beam 4. Low Beam

QI is the predominant automotive lighting technology today. Legal in the U.S. since 1984, it uses a small bulb that resides inside a reflector/lens assembly. Thanks to modern sealing materials and techniques, the reflector is far less likely to corrode from moisture intrusion. The high-temperature quartz glass envelope allows the filament to remain at a much higher temperature, for a light that's closer to natural daylight. The higher temperature means a lot more light for the power consumed, but also makes the tungsten filament evaporate and redeposit on the glass, gradually reducing light output. To combat this, halogen bulbs are filled with iodine or bromine rather than the customary inert gas. The halogen combines with the tungsten vapor coating the cooler glass, then disassociates when it touches the hot filament, basically redepositing the evaporated tungsten back where it started.

Manufacturing these cylindrical bulbs is very high-tech. After the filaments are sealed to the glass at the bottom, most of the air is evacuated from the top. While a propane flame heats the neck in the top of the bulb to a semiliquid state, a jet of liquid nitrogen cools the base to minus 321 degrees F. Then a pellet of frozen gases is dropped in. Instantly, the hot, soft glass at the top is crimped, sealing the envelope. When the temperatures equalize and the gaseous pellet boils, the pressure inside rises to 4 to 5 atmospheres. The H13 high–low beam lamp shown in the lead photo is the industry's latest version. Computer vision systems carefully tweak the position of the filaments in each bulb as it's assembled, maintaining tolerances within 0.004 inch—which means replacing a lamp shouldn't require reaiming the headlamp. The high-beam filament sits at the precise focal point of the reflector, providing the best illumination up the road. The low-beam fila­ment sits slightly off the focal point to spread the beam and establish a cutoff pattern to keep glare out of oncoming drivers' eyes. Some quartz-lamp systems rely on the use of a metal shield to provide the cutoff pattern.

The color of bulbs is expressed as a function of the temperature of the light emitted. A QI bulb is around 3400 degrees K, as compared to natural sunlight, which is considered to be around 6000 K. Recently, we've started to see QI lights that have a blue-white color, not the usual warm yellow light. These are aftermarket bulbs with different filaments and glass coatings that attempt to emulate the blue hue of expensive high-intensity-discharge (HID) lights (I'll get to HID lights in a minute). While these bulbs do raise the color temperature, they don't get close to an HID's 5000-plus K color. Oh, and they don't necessarily raise the light output either. So what's the point? Style­—it's one way to spend $20 and acquire the cachet of $2000 HID lamps.

How to Break in a New Car

It’s a thing of beauty: A brand-new car, shiny and crisp. It makes you want to spend the whole evening walking around it. Pretty soon, the neighbors wander over to congratulate you—and to render advice.

Break it in carefully, one says: “No more than 30 miles per hour until it has 1000 miles on the odo.”

“No,” another says. “Drive it like you stole it, if you want it to be fast.”

Others recommend synthetic oil, or nitrogen in the tires, or a mouse-milk oil additive, guaranteed to double fuel economy.

The ritual of breaking in a new car is part of the body of knowledge we refer to as conventional wisdom. It’s not necessarily wise, and the technology of building a modern automobile has evolved to the point where a lot of “wisdom” is obsolete. Few cars specify a break-in procedure anymore, simply cautioning you to avoid extreme acceleration or extended idling for the first thousand miles or so, and there’s little in the way of extra service up front. Some don’t even mandate an oil change until 6000 miles. We think your new ride deserves better. Here are a few tips.

Engine Cylinder Walls

Piston rings don’t rely on their spring tension to seal against the cylinder bores. Instead, combustion gases work their way between the rings and the piston and force the rings outward. During the first few minutes of engine operation, it’s important that the throttle be opened pretty far at lower rpms to provide this high pressure. Otherwise, the rings won’t burnish the cylinder walls properly, and the engine will have high volumes of blow-by—which means excessive oil consumption and shortened engine life. If you’ve ever seen the car jockeys who drive new cars off the end of the production line into the storage lot, or the transporter drivers zipping up and down the car-hauler ramps, you’ll realize that this all-important step has been performed for you many times. If you’re installing a new engine, simply give it a few seconds of wide-open throttle in a high gear. For the first thousand miles, avoid constant speeds and throttle settings. If you commute in normal stop-and-go traffic, you’ll be fine. I advise against cruise-controlled sojourns across Nebraska.

Bearings

The admonition to keep engine revs low for an extended break-in period stems from the days when bearing and crankshaft manufacturing tolerances were far less rigorous and lubricating oil wasn’t nearly as good. While modern engines are assembled to much the same design clearances, the tolerances are much tighter, meaning the variability is smaller, greatly reducing the possibility of a tight spot. Redlining a fresh motor is generally a bad idea, but there’s no reason you shouldn’t drive normally. I would, however, avoid top-speed testing, drag racing or towing heavy trailers for the first 1000 miles.

Oil

I customarily change the oil in a new engine after about 20 miles, and again at 1000 or so. That 20-mile oil, you would think, would look pretty much like fresh oil right out of the bottle. Wrong. It usually looks more like metal-flake paint, iridescent with tiny particles of metal worn off rubbing surfaces inside the new engines. After a few hours of operation, this completely normal phenomenon slows down as the rings, camshaft, lifters and bearings burnish their respective mating surfaces.

Transmission

The engine break-in procedure also covers the gearbox and the clutch on manual-transmission cars. Most cars with automatic transmissions today are factory-filled with ATF and, supposedly, will never need changing. Some manufacturers are so confident of this that they don’t even have a dipstick or a fill hole. If the specified fluid is a more ­normal mineral oil, I’d change it and clean the pan after a thousand miles or so. The organic linings on the clutch packs shed a lot of debris, and it generally just turns into sludge that lies in the pan. You don’t want wear metals and sludge to get picked up by the pump and start circulating in the expensive bits.

(Photograph by Frederik Broden)

Brakes

New brake pads on new brake rotors don’t really require a break-in procedure. The texture deliberately left on the surface of the iron discs will grind down the fresh surface of the pad material within a few miles. Even so, refrain from high-speed stops or dragging the brakes for a few hundred miles. Racing pads, however, need to be heated up enough to fade and then carefully cooled off, which removes the top layer and provides better fade resistance.

Interior

Avoid the impulse to slather the interior trim with shiny protectants, which can leach the plasticizers out of new vinyl and increase the likelihood of age-related cracks. On the other hand, a generous dousing of Scotchgard on the cloth upholstery and carpets will keep dirt, pollen and mildew from clinging.

Paint

In years past, it was considered a good idea to not wax a fresh paint job for 90 days, to allow the paint to fully cure and any solvents to escape without being trapped under the wax. Modern catalyzed clear-coat paint is as hard as it will ever be as soon as it cures, before the car ever leaves the plant. Applying 3M Paint Protection Film to the leading edge of the painted bodywork will go a long way toward minimizing stone-chip damage. Otherwise, a good coat of wax will repel water, atmospheric pollutants and dead bugs.

NOW YOU KNOW: Is synthetic oil too slippery for proper break-in?

Conventional wisdom says that a new engine should be broken in on conventional mineral oil, regardless of your intentions to use a synthetic for the long haul. The conventionally wise say that synthetic oil is too slippery and won’t let the microscopic high points properly lap themselves in, delaying the break-in process. I say rubbish. Many modern cars, notably such high-performance marques as Porsche, Ferrari and Corvette, are factory-​filled with synthetics. You can bet that somebody has determined that the break-in process will proceed normally with synthetic in the sump of these ultra-high-performance engines. And that goes for your Toyota or Jeep as well.

Nonetheless, I do prefer to use a mineral oil for break-in. It’s $3 a quart versus $7, so I don’t mind changing it after 20 miles and again at 1000.

I would not, however, change the factory-fill synthetic back to mineral for break-in. Those vehicles typically have carefully assembled engines with instructions to do the first oil change at the regular interval, which could be up to 10,000 miles. In those cases, I simply change the oil early, before 1000 miles, just to be safe.

Synthetic oil is a superior product, particularly if your engine operates at the extreme ends of the temperature scale: high-temperature climates, towing or racing. But like any oil, synthetic will become contaminated with atmospheric dirt, wear particles, carbon, partially burned fuel, water and acid. Eventually, even if the oil itself is performing properly, all this extra junk will manifest itself as engine wear.

Also, the first oil change invariably reveals small particles of gasket sealer, chunks of unidentified plastic, the occasional metal flakes that weren’t cleaned off before assembly and even the odd washer or nut. It’s pretty scary. Better this junk come out sooner rather than later.

What You Need To Know About Grease

Q: I shot a bunch of expensive marine-style grease into the bearing buddies on my bass-boat trailer last fall. It was recommended to me by a marine mechanic as the best product for my trailer, because the wheels get dunked regularly, and this particular type of grease is supposed to be more water-resistant. I finally got a chance to go fishing last weekend and noticed that the grease cups had all leaked oily snot all over my brakes. So instead, I spent the afternoon cleaning and repacking all six wheel bearings and replacing all of the greasy, oily brake shoes. Can you suggest a brand of grease that won’t do this?

A: You mentioned the brand of grease in your letter, which I removed, because it's a perfectly good product, and the correct one for your application. Specifically, i t ' s an aluminum-complex grease, and this type of grease has excellent performance when there's a chance of water contamination, like on your trailer.

A primer about grease: It's basically nothing more than a heavy oil mixed with enough soap to make it stringy and clingy enough to remain in place as the bearing spins. This will ensure the bearing's rollers or balls are constantly covered in the oil. The soap is based on a variety of compounds, notably lithium or aluminum complexes for most of the greases used in cars, trucks and boats.

Problem: Not all the soaps are compatible with each other. This causes the soap and the oil to separate, letting the latter settle to the bottom of the cavity the bearing is in. No surprise—a lot of grease caps have a poor metal-to-metal seal and will let the oil leak out after some weeks. Like yours did.

Your wheel bearings were probably originally lubed with a lithium-12-complex grease, a perfectly good grease for wheel-bearing use, even on a boat trailer if it’s maintained. Shooting some more grease into the bearing cap with a grease gun isn’t a bad idea. Shooting an incompatible grease in is.

This counterpoints the need to completely remove the last vestiges of old grease from a bearing whenever it's repacked. Yes, you want to remove the dirt and wear particles, but odds are you won't know what kind of grease the last mechanic used.

I'm not going to print a huge grease compatibility chart here, although that kind of information is available on the Internet. If you always clean the bearings properly before repacking, it will never be a problem.

Don't have a nice parts-washing sink with recirculating solvent handy to your driveway? It's still easy to clean the bearings properly. Remove the bearings, inner and outer, and any shims, lockwashers and clamp nuts. The bearing inner or outer races can stay pressed in place, however. Scrub the inside of the bearing cavity with paper towels until you've got as much grease out as possible, and wipe as much off the bearing itself. Dump the used paper towels. My favorite bearing cleaner for the field is a disposable aluminum pie tin, but any suitable vessel will do. One at a time, clean the parts in solvent, whether it's turpentine, paint thinner, kerosene or even hot, soapy water in a pinch. Keep the bearings separate so they go back into the same wheel-don't mix and match. Use a cheap disposable paintbrush to scrub all the old grease out. Let dry, then finish with a quick blast of carb or brake cleaner to get the last dust off. If you have compressed air, you can use it to dry the bearings as long as you don't spin them into destruction. Pack the bearings by hand, and fill the cavity approximately halfway with grease.

How To Repair A Cracked Vinyl Dashboard

Q: I have tried to take exceptionally good care of my 2006 Jetta’s interior and exterior, but this winter a 1/4-inch crack appeared in my dash. It almost looks like it has been cut, and I have no idea where it came from. My greatest concern is the crack getting larger. What are my options?

A: That dash consists of a vinyl fabric over a foam padding. Sunlight, excessive cleaning and incessant slathering with protectant can leach all the vinyl-chloride plasticizer out of the vinyl—which then gets brittle and cracks. Eastwood (eastwood.com) has a repair kit that will let you make a pretty good repair if the crack is small, especially if it’s in an unobtrusive place. Unfortunately, odds are the vinyl will crack elsewhere fairly soon. The only real cure is to recover or replace the entire dash, which is neither simple nor cheap.

Your other solution is one of those cheesy-looking fabric dash covers. You also could go retro and glue on some shag carpeting . . .

Next time, don’t use anything except a soft rag and warm water to clean the dash. Avoid harsh cleaners like 409, Janitor in a Drum, ammonia, alcohol, window cleaner or even detergents. They’ll leach the plasticizers out of the vinyl coating prematurely.