2005 mercury 40hp hard to pull and to start

[Polar_Kraft]

Hoping to get your opinion on an issue with my recently purchased 2005 Mercury 40 HP 4-stroke pull-start outboard (3-cylinder, carbureted).

The pull starter is extremely difficult to pull. It takes both hands and a lot of force. Is that normal for this engine, or should it pull much easier?

Also, the engine consistently requires 5–7 pulls to start, whether it’s cold or fully warmed up. Is that considered normal?

Here’s what has already been done:

• Carburetors cleaned and rebuilt
• Fuel filter replaced
• Fuel hoses replaced
• New primer bulb
• New spark plugs, correctly gapped
• Valve clearances checked and within specification
• Fuel tank emptied, cleaned, and refilled with fresh 91-octane fuel
• Engine oil and filter changed
• Gear oil changed
• Water pump impeller replaced
- Compression 150/140/150

Once the engine starts, it runs like new. It idles smoothly, accelerates instantly, never hesitates or misses at any RPM, and performs flawlessly on the water.

Based on these symptoms, do you have any suggestions about what could cause the very hard pull and the excessive number of pulls required to start?

Thank you very much for your time and expertise!

 

[racerone]

Perhaps find an electric start kit.

 

[Polar_Kraft]

Perhaps find an electric start kit.

Perhaps find an electric start kit.

Upgrading to electric start would cost approximately C$2,500, which is more than the motor is worth.

I don’t feel it’s worth investing that much just to save 5–7 pulls, perhaps only 10–12 times a year, on an engine that’s already 21 years old.

 

[racerone]

Look into fitting a manual primer valve,----Used on many Johnson / Evinrude models.-----Bypasses the choke set up;----Keep looking for a blown up donor motor.---$500 or less.-----Your location?-----Motor serial #?

 

[Polar_Kraft]

Thanks for the input, but I’m trying to determine whether what I’m experiencing is normal. If it isn’t, I’d like to identify the underlying cause before attempting any modifications.

Unfortunately, most of the experts I’ve consulted have all given me the same answer: “It’s a difficult engine to start.” I’m not convinced that’s an adequate explanation.

Serial number: 1B199362