1973 Johnson 115hp - repair manual suggestions

[wmgraphics]

I bought a 1973 115hp - M#- 115ESL73M S# - J3867259 (what does the "m" stand for in 115ESL73M?)

I need a repair/parts manual that is easy to follow. Engine has sat for several years. The tech I hired to inspect the boat said it had good compression, spark, lower end fluid looked good.

The things he found wrong was... fuel pump was not working. He said the rubber most likely fell apart after sitting for so long. Should I get a repair kit or just by a new/rebuilt one. He said to repair can be a real pain.

The starter was bad. He said something about it giving off a big surge when he tested it. Could this be a solenoid problem? Should I just replace it or repair kit and where can I find one.

The carbs should be rebuilt. Where can I find these (2) and what should I really be looking for in these kits?

Should I change the lower end fluid and seals?

Other than spark plugs, impeller and maybe thermostat is there anything else I should replace/ check or do to this motor before attempting to start it? I'm kinda nervous since it sat for so long and I am not the most mechanically inclined dude. Please help.

 

[jonesg]

Re: 1973 Johnson 115hp - repair manual suggestions

Get the factory manual, I just got one off ebay, they're simple as paint by numbers with lots of clear photos.
Look here on Iboats for the FACTORY manual (not aftermkt manual)

or try vintage manuals on ebay, they're usually brand new re-prints.
http://stores.ebay.com/VINTAGE-SNOWMOBILES-AND-SPORTSCARDS

Personally I would swap the fuel pump out and rebuild the old one for a spare, that would give you some experience working from the manual too.

Ditto for the starter if you can afford it, they're not too expensive , they are not too hard to rebuild either.

Get the carb kits here on iboats if possible.
Watch some of the tech videos on Utube.
http://www.youtube.com/watch?v=Wj0la6c5FDg

 

[ezeke]

Re: 1973 Johnson 115hp - repair manual suggestions

I agree with everthing above except the part about the fuel pump. The Service manual says they are not serviceable. (see Page 3-12).

However, the instructions in the first thread on this forum will help you do it anyway:

http://forums.iboats.com/showthread.php?t=240864

 

[wilde1j]

Re: 1973 Johnson 115hp - repair manual suggestions

I would get the starter rebuilt by an auto electric shop ... they can do it right for a fraction of new.

 

[wmgraphics]

Re: 1973 Johnson 115hp - repair manual suggestions

Thanks for all the tips!

What do you think I should do about the lower end, replace the gaskets while I replace the impeller or not? As for replacing the fluid, where can I find a pump and what type of fluid should I buy?

As for the starter I did find some kits, but I am still wondering if that is what giving off the surge or is it the soleniod? Anyway does anyone know how to repeat the test the techs do to check this problem?

Like I said I found a few of the parts I need on this sight but they don't have everything. Can anyone recommend some place that can fulfill my existing orders?

Thanks,

Mike

wmgdesign@yahoo.com

 

[wilde1j]

Re: 1973 Johnson 115hp - repair manual suggestions

For the starter, start by making sure ALL heavy wire terminations are bright, clean and tight (this includes grounds). Most starter issues turn out to be wiring issues, with the starter and solenoid way down the list for problems. If everything is OK in the wiring dept., make sure you have a good, fully charged battery. Then try starting and let us know the results.

The solenoid is easy to test. Just use heavy wire jumpers from the hot pole to the switched pole ... if the starter operates OK then, the solenoid is bad.

Walmart usually has pump and gear oil (Penzoil), which should do fine.

For the water pump, replace all soft parts and the pump housing/liner if scored, likewise the ss wear plate. You can never go wrong with a complete kit, especially given the cost vs the time to get at it.

Any BRP dealer can supply all the parts you may need.