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    2002 Suzuki DF115 power tilt repair - seals and removal

    My 2002 Suzuki DF115 power tilt piston is leaking. Very milky fluid and the tilt moves very slow until it gets about halfway raised and then it moves the motor OK. This is a single ram unit, not 3 ram and there is not much info online about working on this style. The problem appears to be a...
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    Suzuki DF115 overheating high RPMs

    Greetings, Hoping some folks can provide insight and suggestions on my overheating issue. I have a low hour 2001 DF115 that has developed an overheating issue at high RPMs (~5000). Couple times on the water get the alarm and engine cuts back. I stop, turn the engine off, and I can restart no...
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    yami f60 won't start w. partial control connection

    Wasn't sure how to word the title, but I'm trying to run the engine with only the primary wiring harness connected to do some maintenance but can't get it to turn over. The throttle, gear shifter, and tachometer are disconnected and the ignition harness is connected. The engine wont turn over...
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    5hp on the seabed - please help!

    Apologies for cross posting. My 5hp 2 stroke got flung off transom at FULL throttle (~10mph) as result of an unexpected and immediate 90 deg turn. So although I'm lucky it didn't knock me out, its now in about 20-40' of SALT water and I'm planning to dive and recover it from my 12' skiff in the...
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    submerged 5hp 2 stroke in salt water

    5hp 2 stroke got flung off transom at FULL throttle (~10mph) as result of an unexpected and immediate 90 deg turn. So although I'm lucky it didn't knock me out, its now in about 20-40' of SALT water and I'm planning to dive and recover it from my 12' skiff in the morning (~10 hours from now)...
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    Engine is on the seabed advice needed - 5hp 2 st

    5hp 2 stroke got flung off transom at FULL throttle (~10mph) as result of an unexpected and immediate 90 deg turn. So although I'm lucky it didn't knock me out, its now in about 20-40' of SALT water and I'm planning to dive and recover it from my 12' skiff in the morning (~10 hours from now)...
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    epoxy made for fuel exposure - carb repair

    Hi, I posted in the Suzuki forum with one good suggestion but thought I'd check in with the johnnyrude crowd. I have a couple mid 80s 15hp and thought there might be some insight in this forum given some comparable design features. Anyone know of a good epoxy made for fuel exposure that I can...
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    Internal carb repair - What bonding agent to use (2000 5hp)

    Hi, I have a 2000 Suzuki 5hp that needed a carb overhaul. Unfortunately I broke one of the aluminum arms that supports the float hinge pin. I have the part and could reattach it easily if there is a bonding agent that will resist having the exposure to the fuel. Can anyone refer me to a material...
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    '85 johnson 15 hp - powerpack ground sparking

    Greetings, I rebuilt an '85 Johnson 15 hp over the winter and finally got it put back together and ready for testing. It started up easy enough but I noticed a consistent spark coming from the powerpack ground. My first thought was that the ground was in the wrong spot as I put the ground under...
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    DOH! Broken bycass cover bolt - 1985 15 hp

    In my haste to attach a ground wire to the upper aft bypass cover bolt my impact drill was in the tighten position and snapped the bolt. Is it imperative for me to replace this bolt or could I get by with a workaround? Could I just solder the interior of the bolt hole to secure everything? If I...
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    '85 Johnson 15 Electrical wire size/replacement for kill switch

    One of the kill switch wires for my pull start '85 Johnson 15hp are badly chewed up and need to be replaced. I just need to splice in a section of wire but do not know if there is a specific size/type that I need. It appears I would need to replace the whole assembly to resolve this minor issue...
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    '85 15 hp Johnson -motor cover to steering bracket seal question

    I'm putting together a parts order and the parts diagram shows there is a seal between the bottom of the engine cover and the steering bracket. My engine lost this long ago and I cannot see where it should even go. Anyone know what this part is for, how important it is and where it is placed on...
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    Johnson 15 rebuild - pistons too tight?

    Hi, I've been down the long low compression troubleshooting road on my '85 johnson 15 which ended with 2 new GLM cast pistons standard size. After finally getting them inserted into the cylinders they seem too tight. I can move them but there is definitely friction and it is not a smooth pull...
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    Johnson/Evinrude 15/9.9 hp tiller/throttle

    I have an '85 Johnson 15 and would like to convert the gear throttle to a cable throttle. I'm primarily doing this because the current throttle gears have several broken teeth making the throttle pretty much shot, and from what I've read the cable throttle is mechanically superior. Looking at...
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    convert throttle on '85 15 hp from gears to cable style

    Anyone know if the gear throttle from the earlier Johnson 15/9.9 (1985 in this case) can be converted to the cable style throttle (1986 and later)? I need to replace the gear component of the throttle and figured I'd look into making this conversion. The part that the tiller handle connect to...
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    Grounding small outboard wires

    Hi, I recently removed the electrical components from a Johnson 15 pull start and not that I'm replacing them do not recall exactly where to ground the powerpack and coils. I'm pretty sure they wree on the bottom of the exhaust and bypass covers but don't know if makes a big difference...
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    clogged grease tube (not the zerk)

    Hi, Anybody have any recommendations for cleaning out a clogged grease plug (not the fitting aka zerk but part where grease goes from zerk into the mechanical part that needs to be greased)? After I finally got the fitting off there was a hard white crust in the tube that I dug out with a...
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    Johnson 15 - scored piston and delaminating crankcase

    Hi, Building on a recent thread I started (http://forums.iboats.com/showthread.php?t=525675&p=3569412#post3569412) when I found some scoring in the lower cylinder of my '85 Johnson 15. After taking it apart the lower pistons is scraped up pretty good and needs to be replaced, but before I do...
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    Johnson 15: Use '87 piston in '85 powerblock?

    Greetings, Looks like I need to replace a piston in my '85 johnson 15hp and was wondering if anyone can tell me if there is any flexibility to use pistons from close but different years. Looking at part numbers, only '84 and '85 match, which could be difficult in tracking down a good used one...
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    Outboard spraying water into boat

    Hi, I've been lurking here for a while and figured I'd post up a couple issues I'm dealing with on my small 12' skiff. Hopefully someone has the solution I'm looking for. As I understand it, the plate at the base of the midsection should be even with the bottom of the stern. If t is lower it...
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