115 Johnson Ocean Pro Won't Stay Running

[marlin35]

Hoping for some help from some of the gurus around here!

1997 Johnson Ocean Pro/Runner
60 deg-optical ignition

My symptoms...
Can start and will run for 15-20 secs...then acts like it floods out..cannot crank choked or not..wind up with raw fuel/oil coming out of exhaust ports...can drain the bowls and start it up for 15 secs running at high idle only...same thing happens again..checked the plugs and they are wet(bottom two worse than the top)...I am at my wits end unless it something electrical.

Heres what I have done to date...

rebuilt all four carbs--new needle/seat, gaskets, weighed the floats to make sure they were not compromised...adjusted float levels-closed and drop level to specs--needle/seat in fuel pump/vapor separator...fuel is not restricted...bulb does not go down eliminating a starvation issue...raw fuel/oil will drip out of the bottom two carbs when starting is difficult.

I appreciate any advice that you folks may have and are willing to share!
Thanks in advance!

Scott

EDIT: forgot to mention i have had the boat for several years, motor has run flawlessley...did not get much use this winter, started it several times through the winter and had no problems...went to fire it up the other day and have been fighting this ever since.

 

[Yamajoe]

Re: 115 Johnson Ocean Pro Won't Stay Running

(raw fuel/oil will drip out of the bottom two carbs when starting is difficult.)

You have a float level issue and or stuck open float valve. I know you did the carbs, but some crud or incorrect setting of the float valve is not permitting the fuel to be cut off when the bowl is full.

 

[tashasdaddy]

Re: 115 Johnson Ocean Pro Won't Stay Running

what he said or. your primer solenoid is malfunctioning. the lever on the primer should be in the postition in the picture.

 

[marlin35]

Re: 115 Johnson Ocean Pro Won't Stay Running

That was my initial thought as well..pulled the bottom two carbs off and rechecked them...clean as a whistle and float levels were reverified and well within the recommended specs by the Clymer manual...checked the shut off level and the "drop" level of the floats...any other thoughts re: the floats? I DUNNO!

With regards to the primer solenoid...the valve is in the down or 6 oclock position...this is one of the features that I am not very familiar with on these style motors. Any thing to investigate on this or is it a remove replace type of part?

I really appreciate yalls help as I am trying to get this boat on the water for the spring...Thanks again for the time!

 

[tashasdaddy]

Re: 115 Johnson Ocean Pro Won't Stay Running

if the red valve is in the 6 oclock position, the primer is letting gas into the intake flooding the motor. it should be like the picture back center line with the body. that's why it is flooding out. this should cure your problem. let me know.

the primer replaced the old choke butterflies in the carborators, pushing in the key activates it, like the old choke plates.

 

[Faztbullet]

Re: 115 Johnson Ocean Pro Won't Stay Running

Check the hoses on the manifold balance tubes. If you have fuel running out of them the vapor separator is flooding or hose in wrong place..

 

[al27023]

Re: 115 Johnson Ocean Pro Won't Stay Running

Please let me jump in here and provide some more info on thsi exasperating problem; the prob started with leakage at service valve and at fuel filter in fuel module. replaced service valve and seals in filter housing and then started the trail thru the carbs, to the float in the vapor separator (float was high), and today did the solenoid unit (no parts used in vapor separator or solenoid unit, just reassembled with all parts looking satisfactory).
This solenoid is mounted vertically and 6 o'clock positon is in line with solenoid body (the brochure for preventive maintenance valve 175158 says 6 o'clock positon is run position and ccw to about 2 o'clock is start position).
No obvious problem found in solenoid housing and would like any further comment on where else to look besides balance hoses once we try to start this beast again.
By the way, no owner's manual for this motor - how is the service valve supposed to be used? put the cleaner in in the start position?
Is there any other way to get fuel into intake - possibly failed diaphragm in fuel pump?
Also motor runs on fuel oil mixture, not using oil injection pump - appears to be disabled per the Clymer manual instructions.
Thanks for any input!
Al (Scott's dad)

 

[Yamajoe]

Re: 115 Johnson Ocean Pro Won't Stay Running

Uderstand your frustrations but hang in there; The primer solenoid resistence should be 4-7 ohms. connect a meter between the purple/white and black leads. If not replace the solenoid. Check the fuel pump pressure, install gauge between the pump and Carbs. I don't have the spec. readings someone maybe able to give us these. Recheck the advise provided so far. good luck.

 

[al27023]

Re: 115 Johnson Ocean Pro Won't Stay Running

Thanks - checked solenoid resistance yesterday, right at 5 ohms. Will set up fuel pressure gauge for fuel pump sometime today. This could be a good lead since vapor chamber float level was higher than spec and resetting didn't change operation. Clymer manual says 3 psi for VRO pump at 800 rpm is sat, don't know if we can make it run long enough to read or if I have a gauge accurate enough to read 3 psi.
Any thoughts on pulse limiter affecting fuel issues?
Thanks again.

 

[CharlieB]

Re: 115 Johnson Ocean Pro Won't Stay Running

Is it possible that you reversed two of the three small hoses on the fuel solenoid?

Switch the fuel SUPPLY line to either of the carb lines will provide a continuous fuel flow to that carb, and could possibly overcome the valve seat and enrichen the other carb, basically flooding the engine.

Double check your fuel lines.

 

[al27023]

Re: 115 Johnson Ocean Pro Won't Stay Running

This particular solenoid is part of a fuel module; it only has two small lines (1/16" ? hose connections) to intake banks and an integral ferrule with o rings cast into the body that plugs into the module and is held with 2 SM screws.
Have FP gauge setup waiting for son so we can check FP, solenoid lines and vapor lines to balance tubes when we can get it running which may be for only a short time, if it not fixed yet.
Thanks again for all inputs.

 

[daverk]

Re: 115 Johnson Ocean Pro Won't Stay Running

Hey had the same problem happen to me and it turned out to be the igniton switch stuck in the prime mode eventually smoking itself.replaced key switch and problem fixed.

 

[al27023]

Re: 115 Johnson Ocean Pro Won't Stay Running

Thanks - wish I had been smarter sooner or you had seen this post earlier.
Replaced ignition switch yesterday and finally got it to run in yard, had found out that kill switch wasn't working and finally that solenoid wouldn't pick up all of a sudden. (Ignition switch is mounted on center console at about 20 degree angle from horizontal, so catches all the stuff from the sky) Had even got some high class experience and was looking to power pack, but started with ignition switch.
Don't have 3 psi out of fuel pump, but it runs; could primer bulb (check valve) in fuel line keep the pump pressure from showing on gauge? Tapped into line at connection on fuel module.
Thanks again to all.

 

[al27023]

Re: 115 Johnson Ocean Pro Won't Stay Running

Still trying to get this thing right.
To date - replaced primer bulb, fuel filter (cartridge type), will now run about 3-4 min at idle then starts to run rough and die.
Checked vacuum reading from tank while running - barely shows a vacuum < 1"; fuel pressure is low - after pumping up to 4-5 psi will slowly drop to around zero and eventually die. Once it starts to die, pumping won't revive it.
Pulled fuel pump off fuel module/bracket and disassembled; appears main diaphragm is damaged.
OMC parts says pump kit (436205?? extremely hard to read info on the pump kit breakdown chart in the accessories listing for Johnson) is not available - anybody know of source for the diaphragm or if a standard pump can be installed (oil injection disabled). Pump is listed as 0438400 at $350 plus.
Any more thoughts?
Thanks again.
Al
This pump is attached to fuel bracket with a built in ferrule with two o rings to seal the pump output.