1989 Johnson 110 Doesnt Run with Cover on

[johnson1989]

This motor has been a bear. This motor ran great first time in the water but alarm went off for overheating. We did a complete new water pump impeller ect. Also replaced the Tstats. Still had the overheat issue, Water reflectors last thing that could cause overheating. We took the head off on the side overheating and replaced the Water reflectors. Overheat issue now is fixed. We took it out to test and it was bogging down and doesnt run barley at all. We didnt understand. It runs like a champ with the Cover off, as soon as you put it back on, or just set it on top it has no power. We double checked no wires pinched, no tubes being cut or pinched. Brought it back out and same deal. It runs great with the cover off but as soon as its on or even placed over it runs bad. Need Help here or suggestions. From what I have heard this is probably a Exhaust Leak or some type of Air restriction. I need some help on where to start. It didnt have this issue untill just after the Water Reflectors being repalced.

Thanks~!

 

[ezeke]

Re: 1989 Johnson 110 Doesnt Run with Cover on

There are some fairly large metal latch plates on the cover just about where the plugs are. Make sure the wires are not in contact with them.

More likely issue is exhaust. Make sure that the exhaust seals at the gearcase are back in place. - see the exhaust housing diagram for your engine here: http://epc.brp.com/default.aspx?brands=ej&lang=e

You could also be getting some exhaust if the grommet was not replaced on the shift rod at the gearcase.

If the exhaust is not coming from that, there are a few other spots to check.

 

[F_R]

Re: 1989 Johnson 110 Doesnt Run with Cover on

That was a common occurance on older V-4s than yours. The culprit on those was when somebody worked on the water pump and left the seal off the top of the pump housing which allowed exhaust to go up the drive shaft tube and out under the hood. You have a similar problem, but I can't pinpoint exactly which seal is missing. But maybe this will put you on the right track

 

[johnson1989]

Re: 1989 Johnson 110 Doesnt Run with Cover on

Thanks for the input Guys.

I did replace both exhaust seals on in the lower unit.

The water pump kit also came with a new gromit for the shift rod so I do recall the seals you are talking about. I will have to look at the diagram and see. Funny thing is this didnt happen after the pump/ stats where replaced. It happend after the water reflectors where replaced. But it could easily be an issue that just came about from having the lower unit off. I will check and let you guys know after tonight.

 

[johnson1989]

Re: 1989 Johnson 110 Doesnt Run with Cover on

I replaced #24 and #30 on the Exhaust Diagram. I will drop lower unit to see if these are still in good shape

 

[johnson1989]

Re: 1989 Johnson 110 Doesnt Run with Cover on

This was a new pump install not just impeller. So I would assume # 72 or #53would be the areas on the lower unit picture that could be causing the problem?

 

[johnson1989]

Re: 1989 Johnson 110 Doesnt Run with Cover on

Should I check to see if any intake areas are clogged or have issues? Where other then #30 should I look?