1994 Johnson 150 looper issues

[jwellcraft]

Just completed a full rebuild of this motor and the first trip out all went great and got 2.5hrs but then on my second trip today all was going great until the ending part of the trip. As I was heading back to the dock the warning horn srarted doing a constant beep but those very rapid ones not like the regular low oil, no oil, overheat or fuel starvation alarms and the tach was jumping with the beeps and went up and down and even dropped to 0 sometimes but would catch back up for a while then start again. The horn even did this with the motor off but key in on position (bad horn maybe)? Anyway continued back and running around 3,000 rpms the motor quit but not like the seize type of stop, it just got lower and lower before it shut out and wouldn't re-start. It was getting fuel but I didn't check the spark on the water so I got towed in. I got home and tried it again and nothing just rolling and rolling. I disconnected the black and yellow wires up by the voltage regulator and the power pack just to see and tried it and it fired up but the horn was still doing those rapid beeps and tach wasn't registering. Then noticed the stator wire harness looked a bit chaffed and old and was touching the block so I lifted them up a bit and it ran fine for a while with no stalling then starting stalling after a few seconds again. Could these stator wires touching the block or breaking down cause these problems I have experienced?

 

[jonesg]

Re: 1994 Johnson 150 looper issues

Sounds like you found the problem in the wiring.

 

[jwellcraft]

Re: 1994 Johnson 150 looper issues

Sounds like you found the problem in the wiring.

Well I removed the wire loom from the stator wires to get a better look but they weren't any chaffed wires so I don't think that the problem was there. Fired it up today but it only ran for a minuted or so but I think it is definatley an electrical problem though because when it stalls it fires right back for a while again then quits and fuel isn't the problem so I need to do some testing.

 

[jwellcraft]

Re: 1994 Johnson 150 looper issues

Well I tried a few things, changed the power pack but same thing will only start when the kill switch wire is disabled but runs very rough then stalls like before. Changed the ignition switch and same thing, only starts when kill switch disabled and runs rough. Changed the Optical sensor and same thing. The only thing I haven't changed are the coils so any other ideas guys.

Thanks

 

[jonesg]

Re: 1994 Johnson 150 looper issues

Well I tried a few things, changed the power pack but same thing will only start when the kill switch wire is disabled but runs very rough then stalls like before. Changed the ignition switch and same thing, only starts when kill switch disabled and runs rough. Changed the Optical sensor and same thing. The only thing I haven't changed are the coils so any other ideas guys.

Thanks

On the hose, try running it with the big red plug disconnected.
If it will not run the kill wire at the engine is grounding out somewhere between the red plug and the PP.

If it DOES run then the kill wire is shorted between the red plug and the ignition switch, a meter is your freind.

You can fix the rough running after you get it running.
But make sure its running or sparking on all 6, could be the temp sensor wiring is bad too and knocking 3 port cyls out.

Its not the coils.

 

[jwellcraft]

Re: 1994 Johnson 150 looper issues

Hey thanks jonesg, I found the prob today after changing every part that's in the electrical system, stator, rectifier, power pack and coils, encoder and optical sensor and all was the same started only with the kill switch wire disconnected and disconnected the red plug from the forward harness and just bridged the starter and it still ran sloppy. Check the sparks and all 3 port side were out with only the starboard firing and it turned out to be the wire harness which I just bought brand new factory harness was faulty. The only way I got all 6 cylinders firing I had to cut the black and yellow kill switch off from the big red plug and boom,,,,all 6 were firing and started right up and ran like it should, no boggy or stalling so I will have to look around now for another motor harness that I hope is wired right because this is ridiculous that I just spent $200+ on this and it is crap.