Johnson sail master

[saltchuckmatt]

Here is a head scratcher for you. I purchased a 1990 6 hp johnson sailmaster a number of years ago and it seemed to work fine when I bought it. Put it on my boat as a kicker motor and it had a lot of engine noise and didn't run very well. Stuck it in the garage and didn't really look at it again for a couple of years. To make a short story long I pulled the gearcase and the notch in the driveshaft didn't match the water pump impeller. (funny because it pumped water) then I noticed a plug in the exhaust hole next to the propeller. After asking around no one had heard of a stock plug for that spot even though it did not look home made. Turns out someone had put the wrong gearcase on so I bought a used one. This is a long shaft by the way. Put all the right parts on and again ran like crap and smokes out the front of the motor. I tried some other stuff and then decided to take the long shaft and the charging coil off and install it on a 1991 johnson 8hp that I had. Same results. Looked at the parts breakdown and I see that original plug that I couldn't figure out is listed as having to be in in a sail master engine. With this new information I figured I had it "dicked" but when I installed the plug the same condition existed. Crappy running motor with lots of smoke. Cam anyone tell me what is wrong? Motor runs perfect with the short shaft gearcase but like crap with the long shaft set up.

Thanks.

 

[racerone]

Simple-----Some of the " sail " motors used a plug as you have seen.-----This is for blocking exhaust so that you get better thrust in reverse.----They also had an exhaust outlet above the prop to keep exhaust away from the prop.----Careful when you start using the motors with different boats / different parts / different applications.

 

[saltchuckmatt]

Simple-----Some of the " sail " motors used a plug as you have seen.-----This is for blocking exhaust so that you get better thrust in reverse.----They also had an exhaust outlet above the prop to keep exhaust away from the prop.----Careful when you start using the motors with different boats / different parts / different applications.

Didn't really explain why do they run bad with the long shaft set up? Both are the same plug in or plug out. Motors are almost identical, shifter on the front so I know they are compatible. The original engine with the long shaft had the wrong gearcase but the matching part number is now on...5 inch spacer part is the correct part number as well. I've changed 80's Evinrude shaft lengths and never ran into this problem.

 

[racerone]

Oh well-----Post pictures and videos to show the difference from motor to motor.-----These motors in good condition just run so nice.------Yes they are noisier with the exhaust cutout.----I have run a long shaft on a sail boat.---No issues and ran nicely.

 

[saltchuckmatt]

Oh well-----Post pictures and videos to show the difference from motor to motor.-----These motors in good condition just run so nice.------Yes they are noisier with the exhaust cutout.----I have run a long shaft on a sail boat.---No issues and ran nicely.

One more question, I was looking at some Sail masters online and it looked like the 5 inch spacer had some notches in them...mine doesn't. Could that be the problem? (excess exhaust pressure)

 

[Vic.S]

One more question, I was looking at some Sail masters online and it looked like the 5 inch spacer had some notches in them...mine doesn't. Could that be the problem? (excess exhaust pressure)

I have a 6 hp Yachtwin ( The Evinrude equivalent of a Sailmaster)

The exhaust outlet behind the prop is plugged .
There are alternative exhaust outlets in the special 5" extension .

This allows the engine to be mounted on a sailing boat with the prop 5" deeper, so that it does not lift from the water when the boat pitches, without increasing the exhaust back pressure.
These outlets are clearly shown in the picture below

 

[oldboat1]

Motor runs perfect with the short shaft gearcase but like crap with the long shaft set up.

You are removing the powerhead and installing the long water tube when converting?

 

[saltchuckmatt]

You are removing the powerhead and installing the long water tube when converting?

No, I did a water tube extension on the short shaft...they sell them but I made my own. Same scenario though on the original one that is a long shaft to start with. It had the wrong foot so it must have had the wrong 5 inch extension piece. The Evinrude/Johnson parts breakdown does not show the cutouts.

 

[Vic.S]

No, I did a water tube extension on the short shaft...they sell them but I made my own. Same scenario though on the original one that is a long shaft to start with. It had the wrong foot so it must have had the wrong 5 inch extension piece. The Evinrude/Johnson parts breakdown does not show the cutouts.

The cutouts are hidden by the anti-ventilation plate in the diagrams but the extensions for the "sail" versions are listed in the parts lists

68	0396032	EXTENSION ASSY.. 8SRL Only		1
68	0396307	EXTENSION ASSY.. 6SL Only		1

as is the standard 5" extension

59

0396308

GEARCASE EXTENSION. Except 8SRL & 6SL Models 5 INCH LONGER PARTS

1

 

[saltchuckmatt]

The cutouts are hidden by the anti-ventilation plate in the diagrams but the extensions for the "sail" versions are listed in the parts lists

68	0396032	EXTENSION ASSY.. 8SRL Only		1
68	0396307	EXTENSION ASSY.. 6SL Only		1

as is the standard 5" extension

59

0396308

GEARCASE EXTENSION. Except 8SRL & 6SL Models 5 INCH LONGER PARTS

1

My extension is 5 inches. The part you show looks like for a extra long shaft. Are the sail master's supposed to be an extra long shaft?

 

[racerone]

The 9.9 sailmaster was a 10 longer motor.---The 6/8 HP was also available with 10" extension.

 

[saltchuckmatt]

The 9.9 sailmaster was a 10 longer motor.---The 6/8 HP was also available with 10" extension.

Still wondering why it runs funny with the plug out or in but here are pictures. 1st one is the redheaded stepchild or maybe I should call it a Frankenstein, the second one is the correct model, 3rd one is the 5 inch spacer, 4th is the short shaft that I made into a long shaft that runs great with the short shaft but crappy and smokey with the long shaft just like when the sailmaster does and the 5th , and because it sits next to my Etec is what I call a J-tec. I used to have what I called a Yamarude but it was to heavy and I'm not a big 4 stroke fan. Can you tell I took a little more time with the Yamarude!

 

[oldboat1]

Think I'm lost....
The 8 is too shallow in that bucket -- looks like full to the top would be minimal for running.

That mount looks very familiar to me -- think it is a Chrysler mount. I use in on the swim platform of my old cruiser -- note that the hole in the supports holds a steering tube if you want to get independent steering for the kicker (much improved control).

I also have rigged a water tube extension on one of my 9.9 Yachtwins, after using it as a regular shaft. Believing the connection has to be airtight as well as portable (for my use), I used a joint made of tight fitting fuel hose to join the cut pieces of water pipe with a splint and clamps for rigidity. That arrangement works well.

 

[saltchuckmatt]

Think I'm lost....
The 8 is too shallow in that bucket -- looks like full to the top would be minimal for running.

That mount looks very familiar to me -- think it is a Chrysler mount. I use in on the swim platform of my old cruiser -- note that the hole in the supports holds a steering tube if you want to get independent steering for the kicker (much improved control).

I also have rigged a water tube extension on one of my 9.9 Yachtwins, after using it as a regular shaft. Believing the connection has to be airtight as well as portable (for my use), I used a joint made of tight fitting fuel hose to join the cut pieces of water pipe with a splint and clamps for rigidity. That arrangement works well.

Plenty of water when you fill the bucket, at least for starting and slow in gear running. I purchased the mount years ago from Second Wave in Fremont which was located in Seattle. Campion does provide you with any way to mount a kicker and its done a great job of doing just that. I have no idea what hole you are referring to because there isn't any.

Tube extension. I use the same size soft copper tubing and use a swedge tool on the end. Works perfect in fact super tight and takes quite a bit of force to remove.

I guess this motor thing will have to remain a mystery.

 

[racerone]

Long shaft or short they run the same.----The " sail " motor exhaust was plugged above the prop.-----5" or 10" extensions redirected exhaust above the prop.----Not sure why you are having these issues.

 

[oldboat1]

I have no idea what hole you are referring to because there isn't any.

The hole(s) I refer to are in the supports for the trolling motor mount, ahead of the mounting plate. The steering tube and ram goes through those holes horizontally. I tried to find a pic of mine but not coming up with one.