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    flywheel removal

    My 1986 Johnson 150 HP uses 5/16-24. I just purchased a few grade eights 2 inches long. I am thinking yours are the same given the puller was a single OMC part number used across all engine sizes.
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    Johnson 150 Rebuild/Remanufacture Guidance

    OK, I was able to get the "Frame and Seal Assembly" bolts removed and I slid it out the front of the powerhead and above the "Lower Housing Cover". This seems to give me a little bit of access for a Dremel. I'll have to research the Dremel Cutting Wheels for one that will cut...
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    Johnson 150 Rebuild/Remanufacture Guidance

    How do you get your Dremel and blade close to the powerhead mating surface? Is there a way to drop the "Lower Housing Cover" and/or the "Frame and Seal Assembly" (p/n 0392494) ? I currently have everything free except the two long bolts that snapped. I'm trying to pull the powerhead with a...
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    Johnson 150 Rebuild/Remanufacture Guidance

    I'll pick up some Free All at Auto Zone. I twisted the head off two of the six bolts. I'll try and pull the powerhead first, but I am thinking these two bolts may have to be cut off a half inch below the powerhead to get the head to pop off. Thanks for the quick response!
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    Johnson 150 Rebuild/Remanufacture Guidance

    Were you able to fill the slot/slit you opened up with the Dremel motor tool and reuse the Adapter Plate, or did you buy a new/used adapter plate and replace?
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    Johnson 150 Rebuild/Remanufacture Guidance

    racerone, I believe you confirmed below that the wee hole would be drilled in the Adapter and close to the powerhead. NOT in the powerhead as I describe in item 1 above. Is my understanding correct? Secondly, in item 2 above I believe you are telling me that if I am not successful in removing...
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    Johnson 150 Rebuild/Remanufacture Guidance

    Lectro88, Is a breaker bar the same as a "pull handle"? If so, i have been using a 3/8" breaker bar that is approximately 12" long. I have an 18" long 1/2" breaker bar, but I am a bit reluctant to put more torque on the bolt heads. In addition to more penetrant, I may try a little heat today...
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    Johnson 150 Rebuild/Remanufacture Guidance

    So if I understand correctly: 1. You are telling me to measure the bolt length (I successfully removed 3), from below the head to the end of the thread. Then from the exhaust housing bolt head surface, measure vertically (the bolt length) and drill a small hole into the powerhead. The goal...
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    Johnson 150 Rebuild/Remanufacture Guidance

    Three of the six long exhaust housing to powerhead stainless screws are frozen. I got them to move a little, but I don't like the way it feels. It's hard trying to get PB Blaster penetrant to run uphill 3 or 4 inches to the threaded area. I have been tapping the top of the heads and also...
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    Johnson 150 Rebuild/Remanufacture Guidance

    Thanks for your comments regarding my Johnson 150 V6 crossflow. I pulled my boat last weekend. I plan on attempting to break free the key powerhead bolts this weekend. The powerhead was off 17 years ago and I boat in brackish water. I am hoping they break free for me. Any guidance on this...
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    Johnson 150 Rebuild/Remanufacture Guidance

    ct1762, You mentioned that you are going with Vertex pistons. What does your comment, "Vertex are rare for crossflows" mean? Does it mean that Vertex does not cast pistons for crossflows? Possibly due to the piston top/dome ?
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    Johnson 150 Rebuild/Remanufacture Guidance

    Thanks for all the comments. I am reaching out to a few of the individuals mentioned for additional information. Of course, I have more to learn about which piston to go with. Wiseco (forged) or WSM (cast), and now Vertex (cast). Jason at Jays Block Shop seems very nice and knowledgeable...
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    Johnson 150 Rebuild/Remanufacture Guidance

    Thanks for the help with the rebuild shop names (Carson's Marine and Jay's Block Shop). Let me know if there are any other reliable rebuild shops out there, or additional comments for these two shops. Faztbullet mentioned Jason can short block it for me. Is that a complete rebuild of my...
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    Johnson 150 Rebuild/Remanufacture Guidance

    If I decide to tear into this myself, is there a rebuild kit supplier you would recommend purchasing from for quality parts/components? Possibly a supplier that would be willing to answer occasional questions along the way? Can you suggest a shop that focuses on outboard powerhead machining? I...
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    Johnson 150 Rebuild/Remanufacture Guidance

    I need some rebuild/remanufacture guidance for a 1986 Johnson 150 HP crossflow engine I own. The model number is J150TXCDC. I have owned this boat (1986 Boston Whaler Outrage) and motor set up since 2003. The engine has over 1,200 known hours on it. It has one slightly scored cylinder...
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    1986 Johnson 150 HP, Model J150TXCDC Spark Plugs

    My OMC Service Manual recommends Champion Spark Plug QUL77V with the alternate being UL77V. What is the correct plug for this engine? I have been running the Champion UL77V surface gap plugs over the years. My use varies between trolling and running around at 3,000 to 3500 RPMs, not at high...
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    Fuel Leak around Carburetor Bank on 1986 Johnson 150 HP Outboard with VRO

    I have a fuel leak that seems to be at it's worse after I turn off the engine. I am having a difficult time identifying the source of the leak. It seems to be coming from the carburetor bank and related fuel and recirc hoses. I rebuilt the carbs approximately 4 years ago and the engine runs...
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    1986 Johnson 150 (J150TXCDC) Fuel & Oil Recirculation Line Clamps

    I am experiencing a “slow drip” gas & oil leak in front of the carburetor bank on this engine. I can’t easily detect the source, but want to improve the hose clamp situation. Currently, the clamp usage adheres to the OEM Diagrams. It is a mix of BRP Snap Clamps and BRP Cable Tie Clamps...
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    OMC Temperature Switch Removal 1986 Johnson 150HP

    Johnson 150 HP, 1986, Model: J150TXCDC 1. How do I remove the Cylinder Head Temperature Switches from each head? They are functional, but I want to remover them to have my head milled flat. I removed the head cover, and loosened broke the rubber grommet free with PB Blaster, but I am unable...
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    Removing Cylinder Head Bolts and Cover Bolts on a 1986 Johnson 150 HP (J150TXCDC)

    After additional research on this site I believe my cooling system deflectors may be causing an overheating condition. I am now getting an overheat warning only when I run over 4,000 RPM. I replaced the water pump, thermostats, pressure release valve, and springs, two years ago, and believe...
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