1984 Johnson V4 90hp

OBJ

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Re: 1984 Johnson V4 90hp

I think I got a couple good ones that are laying about the shop Scott.....I'll take a look tomorrow. Just to be sure....that would be a 3.5 std bore bored over .030?
 

Chinewalker

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Re: 1984 Johnson V4 90hp

Hi OBJ,<br /> Yep, that's the one. My regular source carries Sierra pistons and the three I have are OEM. ..<br />Thanks!<br />- Scott
 

Chinewalker

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Re: 1984 Johnson V4 90hp

Hi OBJ,<br /> I think I've got my piston issues covered. My local marina guy dug up a pile of used pistons for me to paw through. Found a set each of .030s, .020s, and a couple of Wisecos, too. They were cleaning house of stuff that had been on their shelves for too long and I made out like a bandit!<br /> Thanks for looking...<br />- Scott
 

OBJ

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Re: 1984 Johnson V4 90hp

OK Scott....I looked and the only thing I had that was in decent shape are some .030 over but they came outta' a 175 with a 3.6something std bore. Glad you found what you needed. :)
 

Chinewalker

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Re: 1984 Johnson V4 90hp

FIRE IN THE HOLE!! <br /><br />I finished assembling the 90 this weekend and almost didn't run it. I couldn't find the key to the control box... so I robbed the switch out of another control box that did have the key. Then when I primed up the fuel line gas spurted out of the VRO pump. So, I rebuilt standard fuel pump off the '79 parts motor and instlaled that, rerouting the fuel lines in the process. I actually had the forsight to put the battery on charge for a bit yesterday morning, so I put that in the boat. <br /><br />Now here was the problem. Still lots of ice at the boat ramp and I don't have running water at the shop yet (off for the winter). But I really want to run it and my wife has the car with the hitch (gone for the day shopping with our son) so I can't drag it home to put the muffs on it, either. It's then that I notice the 20 or so gallons of water in the tarp that is sagging into the open bow of the boat. I find a garden hose and my motor muffs and start up a siphon. I kink the hose until I'm ready then let it flow. Not as strong as a faucet but it'll have to do. <br /><br />I kick it over, hitting the key to prime it. No fire. I do notice a dribble of gas coming out of the red lever of the primer solenoid. I pull the cap off the prime and pull out the lever to note that the o-ring seal is a bit dried out and cracked. I put a new o-ring in it and reassemble the primer. Back to the front of the boat, undo the kink in the hose and kick it over again. She barks and stalls. Try it again and it starts and runs! I get about a minute before the water level in the tarp is running low so I shut it off. <br /><br />Now for the ice to go out. There are no seats in the boat at the moment, but I'll sit on an upside down bucket if I have to. I've got a boat ready to get wet next weekend!<br /><br />Nothing like the smell of a 2-stroke after working all weekend. When I started Saturday morning the crankcase was still open. By Sunday afternoon I had a running motor. <br /><br />Thanks to all who helped with advice and encouragement!<br />- Scott
 

Dhadley

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Re: 1984 Johnson V4 90hp

Now that's bad wanting to hear it run! I can relate!
 

Chinewalker

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Re: 1984 Johnson V4 90hp

Okay, finally got a chance to hook up the muffs and run the motor for more than a few seconds. There appears to be a low speed miss, sounds like a lean sneeze. Cylinders 1, 2, 4 are running carbon black on the plugs (running double oil for break-in), but #3 is running wet. LOTS of spark, and I ruled out ignition by replacing coil, plug and powerpack on that side. Same problem. <br /><br />Would a lean condition on that carb at idle (never ran it about 1500-1800 in the driveway) cause the plug to end up wet? Motor seems to smooth out some at high idle - as high as I dared go without a load on it, almost like it was picking up the cylinder as the carbs entered mid-range jets.<br /><br />Am I correct in assuming that an issue with the trigger or stator would likely affect all four cylinders? I have extras of those, too, that I can swap in but they were a little harder to access as I was running out of daylight last night. And, like I said, spark appears excellent in an open air test - bright white/blue.<br /><br />Other than that, the motor sounds good. I'm going to replace the throttle/shift cables as they are a bit stiff.<br /><br />Thanks!<br />- Scott
 

Chinewalker

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Re: 1984 Johnson V4 90hp

Hi All,<br /> I want to thank everyone who helped out on this project over the winter. After a little bit of troubleshooting yesterday I got all the kinks ironed out and the motor ran beautifully!<br /> Kink number one was a mis-adjusted shift rod - it had apparently been backed out a couple turns and I couldn't adjust the cable enough to engage reverse. Dropped the lower and set the shift rod to the proper height from the manual.<br /> Kink number two was the motor was only running on two cylinders. I suspected this when I fired it up on land with the muffs, but I couldn't tell by ear what was happening because of all the barking ans spitting. Once I got the boat in the water it was readily apparent. Idled the boat home and did a little troubleshooting. Starboard bank was nice and warm, port bank was ice cold. Top and bottom plugs were soaking wet. Checked for spark. Looked good. Swapped in a powerpack from one of the parts motors that went into the project - no change. Back to the manual... Discovered I had inadvertantly swapped the coils for top and bottom when I was installing them on the heads! Swapped the wires around to confirm and it ran beautifully!<br /> Thanks again for all the help!<br />- Scott
 

OBJ

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Re: 1984 Johnson V4 90hp

Been watching the thread as it progressed Scott...glad ya' got it going!<br /><br />Just a question....is this going to be a Johnstein or Rudestein??? :)
 

Chinewalker

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Re: 1984 Johnson V4 90hp

Hi OBJ,<br /> When all was said and done, it was probably 75% Johnson. The lower unit is blue, and there are a few blue bolt heads peaking out of the white powerhead... ;) To the uninitiated it'll look like a Johnson 90...<br /> It was a fun project. I've rebuilt a couple hundred motors over the years, but never a V4. Always have that tiny thread of apprehension when diving into something a little different. As your tagline says - use the manual. That was my first acquisition last Fall when I started the project - the OEM manual!<br />- Scott
 
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