Looking for help !

[FLA BASS]

I have a 2004 Johnson 90 (model j90PLSRR/ Ser. 05070640).
Engine starts, idles good @1100rpm in driveway with muffs on. Revs up smooth, no issues. When at boat ramp, it will start, idle, rev up very smooth in neutral, will stall immediately when put in gear (forw.or rev). not “tapering off”, it’s an immediate stall as if you hit the kill switch.
Recent History: Less than 1 hour on Carb rebuilds (ran great on the test run after) then the VRO pump failed, had it replaced at shop. Replaced the fuel/water separator filter. I have had this issue since I picked it up from the shop. Tested compression 130 on all 4 cylinders. No obvious signs of fuel leaks or vacuum hose wear areas or cracks. When starting, sometimes the diagnostic system (oil,temp etc. lights) will flash and beep (never did this before) I have now missed 3 bass tournaments due to this (2 being classics). Really getting frustrated. Any suggestions would be very appreciated.

 

[flyingscott]

What is your compression? Spark on all 4 cylinders?

 

[FLA BASS]

Compression is 130 on all 4 cylinders

 

[FLA BASS]

I will check spark today

 

[flyingscott]

Compression is 130 on all 4 cylinders

Sorry I missed that. Is this an OIS ignition ?

 

[FLA BASS]

Sorry I missed that. Is this an OIS ignition ?

Yes sir

 

[flyingscott]

Yes sir

Is the eye clean and in good working order? None of the plastic bits on the stator are broke are they? Link and sync done correctly?

 

[FLA BASS]

Yes sir

Is the eye clean and in good working order? None of the plastic bits on the stator are broke are they?

I will check and reply soon. I have taken the day off work to figure this out

 

[FLA BASS]

I will check and reply soon. I have taken the day off work to figure this out

 

[racerone]

Use timing light and see if you lose spark when you put it into gear,..----Good idea to drain gear oil , these lower units are not as robust as earlier ones.-----Look for metal bits on the magnet.

 

[FLA BASS]

Use timing light and see if you lose spark when you put it into gear,..----Good idea to drain gear oil , these lower units are not as robust as earlier ones.-----Look for metal bits on the magnet.

Ok guys, so far, the lower unit checks out good. I changed the gear oil and no metal on magnet & oil looked good. Spins free in both directions. I checked the neutral safety switch, it seems to be working properly. The OIS lens is clear with no obstructions, however, it’s sliding bracket seems to be a little “sticky”(this may affect the timing, not sure). I don’t have the tool P/N 434649 to pull the flywheel In order to inspect the stator.

 

[racerone]

The flywheel is held on with 5 bolts.------Usually just pries off. ---No puller needed.

 

[FLA BASS]

The flywheel is held on with 5 bolts.------Usually just pries off. ---No puller needed.

Thank You, will attempt today and reply with results

 

[Faztbullet]

Dont use your fingers to try and pull it off as the magnet force is great and can actually pinch the finger tips off...

 

[oldboat1]

Post spark test results and method. Draw fuel from inboard tank, if that's what you have, and check for contamination -- in spite of fuel filter, which should be checked (water?). (Shops typically use their own clean fuel.)

 

[Faztbullet]

How did you know VRO pump failed?

 

[FLA BASS]

How did you know VRO pump failed?

Would not start and The carb bowls were full of oil. After 2000 they fail to ”pass” oil rather than the old ones that would ”stop” oil and burn the pistons.

 

[flyingscott]

Would not start and The carb bowls were full of oil. After 2000 they fail to ”pass” oil rather than the old ones that would ”stop” oil and burn the pistons.

That makes no sense could you elaborate? When they fail they do over oil the motor. But another culprit is the cap on the oil tank. Did you do the VRO test on it. Was a BRP OMS pump put on it or cheap Amazon/Ebay Junk.

 

[FLA BASS]

OK, again, thanks to all for the info and help. So the stator checked out. Stator resistance =0.185. The timing/sensor guide (OIS) was sticking, no lube on guide. Fixed that. I took it to the local lake for test run…..RESULTS= It will now start good (1-2 cranks), idle at 800-1000, come up on plane well. After running 3000-3500rpm for about 150-200 yards, it looses power and stalls, or chokes down to an idle. Did this consistently 8-10 times. Am I now onto a fuel issue?

 

[FLA BASS]

That makes no sense could you elaborate? When they fail they do over oil the motor. But another culprit is the cap on the oil tank. Did you do the VRO test on it. Was a BRP OMS pump put on it or cheap Amazon/Ebay Junk.

It was a BRP OMS