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    Weak or no spark

    Just got through rebuilding my '93 Johnson 40 powerhead. Went to fire it up last night and no joy. The top plug shows no spark and the bottom VERY weak. Everything was fine when I tore it down due to a scored cylinder. I don't even know where to begin here. Any suggestions? Thanks,
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    OMC Stocking Dealer in Texas

    Does anyone know of a stocking parts dealer in Dallas or Houston? Looking for parts quick. Thanks
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    Gel Seal

    How much is too much Gel Seal? It squirted out the case halves and I can see a little line inside where it squirted out too, but it's not dripping or anything. Is this acceptable? It doesn't seem to dry very quickly and is still gummy after 2-3 days. Please advise. Thanks.
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    Bilge and Live Well Pumps

    I have a '93 Tracker Pro17 and both the pumps are needing replaced. The bilge pump bottom cap (blue Rule) is riveted to a piece of aluminum that is riveted to the transom. How in the heck do you replace that? Drill out the rivets and put screws in place of the rivets? Kinda of a tight space...
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    Locquic and Adhesive M

    I am rebuilding my Johnson 40 powerhead and the company I bought my parts kit from says they include all necessary lubes/sealants. I got Loctite 518 (which I think is Gel Seal) and Pro Marine Pro Gasket Sealer (which I think is Gasket Sealing Compound) and thats it. The book calls for Adhesive...
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    Break-in procedure

    About to finally start a rebuild on a '93 Johnson 40HP, been almost a year and half torn down. Looking for a good break-in procedure, but can't easily find one here. Can someone point me in the right direction? Thanks!
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    What caused failure?

    Ok, I have my '93 Johnson 40 torn down and ready for the machine shop. While they are doing that, I still have to determine what happened. The motor had been sitting for about a year and a half. I cleared the fuel lines and carb bowls, and drained the gas tank. Fresh fuel, and ran it. #2...
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    Cylinder and Crankcase a Matched Set?

    I broke the little ear on the port side of crankcase that the rubber bumper fixes to. I believe this is only to keep the housing from pushing in. I am tempted to JB Weld it back, but before I do I wanted to know if the cylinder and crankcase are a matched set? If not, I will maybe try and...
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    Special Tools for Powerhead Rebuild?

    I just got my manual for my '93 40HP that needs to be rebuilt. It mentions the following "special" tools: OMC Puller Bridge and OMC Small Puller (to remove lower crankcase seals) OMC Cone and OMC Driver (for wrist pin) OMC Rod Cap Alignment Fixture (for rod bolts) Are these critical must-have...
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    '93 Johnson 40

    I am considering a partial rebuild (bore and piston on one cylinder and ring set on the other) on a '93 Johnson 40. I got a quote for $500 for labor only, seemed kinda high. That was bringing him the powerhead, but he would warranty for 90 days. Before making a decsion as to me or him, are...
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    '93 Johnson 40

    Just got a 93 Tracker with a Johnson 40, hadn't run in over a year. Cleared complete fuel system and replaced with fresh, plugs are fine. Fired up and ran about 8 miles upriver beautifully until I started hearing warning horns (don't know what they were, didn't count). Cycled the key, horns...
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    '93 Johnson 40HP Issues

    Anyone know where I can get a service manual for a '93 Johnson 40? I see the link above to buy a printed one, but need one on line preferably as I need it asap. ANyone know of one online? Thanks!
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