2004 Johnson 15hp four stroke repair and/or rebuilding

[Blandshark]

Today I got a great deal! I bought 4 2004 Johnson 15hp four stroke outboards from a boat rental place at a REALLY good price. Thats right, four of them. The reason I got such a good deal on them is they are in bad shape. One runs, but only on one cylinder. One is in pieces in a box and the other two have the lower units removed and from what I was told by the guy who sold them to me they are seized up. Well, I rebuilt a 1993 toyota 4runner engine not too long ago and I went to UTI and they say I am a technician, so I am pretty sure I can make them work.
I am kinda new to outboard engines though so I thought I would share my triumphs and tribulations with you guys and maybe get the kind of advice that will save me from many hours of "figuring it out the hard way" and share it with anyone else who might have similar projects. I just finished my first transom and stringer job two weeks ago too on my 1972 scat craft which has a 72 Johnson 100 (which went pretty well and only took three days.) so I guess I am doing more than just getting my feet wet.
Anyway to the point.........I need a manual of course also I found several places where I can get parts. I would really appreciate comments or advice from anyone with experience with these motors though and don't worry I am positive I will be posting some much more detailed questions as I open these up. I will probably start with the one that runs.
Thanks I look forward to taking part in these forums and hopefully will be out cruizing around in the water soon.

 

[tashasdaddy]

Re: 2004 Johnson 15hp four stroke repair and/or rebuilding

welcome to iboats, i have little experience with 4 strokes, but will tell you to buy the Johnson OEM service manual for your motors.

you can see parts list, and diagrams, and also order part here, http://shop2.evinrude.com/ext/index.aspx?s1=bf6ad09c53cead335fcfd8a6471c0f7f

also aftermarket parts can be bought thru the iboats marine store, just click "Johnson Parts" at the top of this page.

 

[Blandshark]

Re: 2004 Johnson 15hp four stroke repair and/or rebuilding

thanks I will get the manual ASAP for sure. But I started to dissasemble the one that runs on only one cylinder and the lower clyinder was full of oil any thoughts on whether or not it could be a leaky head gasket or rings? Sure would be nice if it was a head gasket they were used by a rental company so it might be a good idea to just hone and rebuild the whole thing. Where could I get a full rebuild kit?...........cheap?

 

[Blandshark]

Re: 2004 Johnson 15hp four stroke repair and/or rebuilding

We'll I got that manual and I tore the first one down to the block there was water in the oil and oil in the cylinders but no marring at all on the clyinder walls and the compression seemed pretty good before I took it apart. The head gasket was pretty shot out though so I figure thats where the real problem lies. So to recap. Two head gasket jobs, some paint and more than likely a bottom end refreshening. Rings and bearings Etc.. just because I allready tore it apart. But this deal of mine is getting better and better. for anyone interested, the four strokes are just like a small car engine on its side. Theres water jackets and oil gallerys in the head, a timing belt, cam, rocker arms, valves, springs, etc.. If you are familiar with car mechanics I highly recommend not throwing it out just because they say they are more complicated. I'll be on the water in no time .......Yeah. well only two more to go then maybe I'll try to figure out the '72 johnson 100 two stroke I have.

 

[Blandshark]

Re: 2004 Johnson 15hp four stroke repair and/or rebuilding

Well just a quick update. I started the one that was running on one cylinder today in a trash can and it seems to run fine on both clyinders. Good for me! Doesn't pee but I figure it just has salt deposits in the head or a bad impeller, quick teardown and cleaning job hopefully. I also completely dissasembled one of the "seized" ones and took it to a machine shop for cleaning and inspection. The guy woking behind the counter told me not to waste my money having them do the work and just get some bottle brushes and clean out the water jackets which were completeley closed off by salt deposits for lack of being flushed and sitting in salt water, otherwise they are in pretty good shape no visible damage at all. So I did, and I tore the bottom end down too for inspection, no major problems there either. So I'm just gonna wait on gaskets and valve stem seals from johnson to get rid of the pesky oil leaks and reassemble and paint it. well thats 2 for 2.
you know I hope i'm not just talking to myself here I wish someone else besides tashasdaddy would reply and at least say hi. Anyone got an extra 14' Morse/Teleflex rack cable lying around