Mack,
Thanks but that is for the big red plug, I have the post 96 setup with all the fancy square and triangle connectors. Some of the colors match up but I will have to check it out more tomorrow. The system check tach will be here Wednesday so I will definitely know when it gets here. I am hoping to get the primer in before this weekend so I can see if that was the only issue with it not cold starting, then off to test the VRO setup and see how the cooling is doing. Hope to be OTW for Memorial Day...got my fingers crossed!

-Svence

Csvencer, this has nothing to do with your choke problem, but does address some other comments in this thread. I came across this article a while back. While I know (and somewhat agree) with what various people have said in the past about VRO (Variable Ratio Oiling) systems, it does seem to make a good case in their defense. In all cases it's well worth the read, just for the information.

http://continuouswave.com/whaler/reference/VRO.html

Well, I am making some progress. New primer came in today and she fired right up. Ran her off some mix gas while I was messing around with the oil line. Tried the clear tube trick and watched the oil get sucked in, VRO is a go! She runs, but of course in the process of getting her ready the trim pump died :( so a new one is on its way...two steps forward, one back. Also changed the lower unit oil, which looked clean so I think all the seals are good.

It's coming, not ready to change the signature yet, but it's coming.

-Svence

Well she is up and running. New trim pump in and we are off. One issue still, but hopefully it won't hold me up. If I run the trim all the way up and let it run for a sec (ie. purging the system of bubbles) it gets stuck up. I can't get it to trim down without first releasing the manual valve on the side. I am guessing it is something to do with the bypass valve in the rams/pump but I'm not sure. Any ideas? For now my plan is to just stop short of all the way.

-Svence

Does the trim motor run when it won't trim down? If not then you may need to adjust the limit switch on it.

Trim motor continues to run, just no movement.

-Svence

Looks like you have a stuck valve, I am not sure if you want to fix it since its a pain, please make sure you bleed the air out of the system, this can cause the issues you mentioned. I am not sure how you doing the bleeding, but the correct way is tilt the motor up and apply the manual (arm) lock to hold the motor upright, remove the filler plug and fill her up, tighten the screw and trim her up and down at lease 3 to 4 times, then check fluid level and top off if necessary. Stuck hydraulic valves are indicative of water contamination at some point or just plain worn out..
If this is critical and holding you up to get on the water I can loan you one my spare..

Mack-
Thanks for the offer but I think I am good for now. The trim fluid coming out was probably 50/50 oil/water so I am sure the valve is jammed up. As far as bleeding it, I did as you described, that's how I found the problem. If I stop right at the top I am fine, keep on going to fill the reservoir and that's when it gets stuck. I am hoping to take her out tonight, so we'll see how it goes. Wish me luck.

-Svence

Good luck and enjoy, Let me know if it acts up on you..