Johnson Rebuild questions

RobDar

Petty Officer 3rd Class
Joined
Jul 19, 2004
Messages
82
I will make this as brief as possible...<br />last year when having trouble with my 1989 Johnson 60...the mechanic replaced relays and tampered with the choke, didn't fix the problem, charged me $400...and also showed me one cylinder had low compression. This year the problems continued...really hard to start...won't stay idling...bogs and dies when you give it gas. I changed the Choke Soleniod and a fuel line and adjusted the carbs so it would at least start, but still would bog when accelerating and was running real rich. The director of one division of our Bass Tournement Circut happened to be fishing with us one saturday and has been a marine mechanic for 40 years. He walked over to my boat...listened to it a second and said..."only running on two cylinders"...he played with the carbs...it now starts every time and runs without bogging out but has much less get up and go. Two others I have talked to said that the old guys diagnosis is very possible. Heres my question...thinking on rebuilding the powerhead. I am not a experienced mechaninc but am told that if I have the manual and an experienced someone to answer questions I should muddle through okay. If ytou guys had to give this job a difficulty rating from 1-10 (10 being a job for a pro) where would you rate it? ( I am capable of about a 5 or 6 rated job). Should I have the cylinders walls tooled or only if they are scored and/or pitted?
 

Dhadley

Supreme Mariner
Joined
Feb 4, 2001
Messages
16,978
Re: Johnson Rebuild questions

Welcome!!<br /><br />Thats a very straight forward design. You should have no problem at all following a good (OE) service manual. <br /><br />Looking at the cylinders wont tell what to bore unless its very obvious. Measuring with a dial bore gauge will. Thats the machinist's job. Once you get it to the bare block you take it to a MARINE machine shop and ask them what needs boring. Dont tell them, ask.<br /><br />Lets take compression first. If one is low, its probably the middle cylinder.<br /><br />What plugs are you running?
 

RobDar

Petty Officer 3rd Class
Joined
Jul 19, 2004
Messages
82
Re: Johnson Rebuild questions

Champion Plugs from the mechanics...just put em in two weeks ago. I have some Bosch Plugs, platinum double tips I am going to order. I actually remember it as being the bottom cylinder...though relying on my memory is always a bit risky.
 

Dhadley

Supreme Mariner
Joined
Feb 4, 2001
Messages
16,978
Re: Johnson Rebuild questions

That motor is pretty sensative about plugs. I wouldnt run anything except Champions.<br /><br />Have you given any thought to a decarb job?
 

RobDar

Petty Officer 3rd Class
Joined
Jul 19, 2004
Messages
82
Re: Johnson Rebuild questions

yes actually I have. I was reading a few other posts last night...one of which was about gas, specifically last seasons gas and the problems it can cause...when I pulled my boat out of storage it still had gas in it. I was under the impression that dumping the gas was part of winterizing it...or at least that was the impression the service guy left me with...it wasn't done and he does not know if Sta-Bill was added or not. My carbs have adjustments...as I understand not all of them do...anyway, one of my carbs, when you adjust the fuel/air mixture, has no effect on how the motor runs. The top carb is very sensitive to adjustment, the middle carb not so much...one the bottom one I think you take the screw out all together and it wouldn't change a thing. A good cleaning? Rebuild? I haven't rebuilt a carb since my wifes 1985 Pontiac. Is there a fuel injection kit I could installor do I have to stay with carbs?
 

papasage

Senior Chief Petty Officer
Joined
Jan 12, 2003
Messages
785
Re: Johnson Rebuild questions

clean carbs . especialey the bottom . the last time i put my 50 hp in the water it wouldnt run past a wake speed .i took the plug out of the frunt of the carb bowl and ran a small wire the size of a spinner bate and ran it in and through the high speed jet . pumped the bule to wash it out and it ran great the rest of the day . just a thought from a red neck gitting by .have don that several times. on a motor that has sat for a while .papasage
 
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