1996 Johnson 115 - won't go over 2500 RPMS - HELP!!

[fishe]

Ok, I believe I have several issues:

I have old gas, don't know if this is the cause of my carbs leaking fuel. Carbs were leaking fuel for a long time with no RPM issues. Purchased Carb kit, installed. Now they are leaking again.

I put new plugs in, advanced auto parts told me the QL78YC champion plugs were discontinued??? Sold me NGK plugs. I installed them. Motor chokes and idles great. No issues starting either. As soon as I give it throttle to get up on a plane it bogs down and quits if I don't let off the throttle. When I pump the ball while doing this the motor picks up a couple rpms but never got above 2500.

Is it the spark plugs? Is it the carbs? Is it the old gas? Is it all of them? HELP!!!!

 

[SparkieBoat]

Re: 1996 Johnson 115 - won't go over 2500 RPMS - HELP!!

fix the carbs for goodness sakes...you probably have a bad fuel pump...get fresh gas and take for a test run after you rebuild/clean the carbs..try pumping the bulb and see if this helps the motor run faster..if it stops exactly at 2500 RPMs but runs good up to there you may have a power pack or temp sensor grounding out...you should also test your over heat alarm by grounding out the temp sensor wire with key in the on position.

 

[fishe]

Re: 1996 Johnson 115 - won't go over 2500 RPMS - HELP!!

some more info, i did replace the fuel line from the filter to the motor, still no rpms

 

[fishe]

Re: 1996 Johnson 115 - won't go over 2500 RPMS - HELP!!

I cleaned the carbs, installed the kits, all four. Would it be the old gas that is causing them to leak again? What about the spark plugs, could this be it? What is the power pack? I'm new to this.

 

[fishe]

Re: 1996 Johnson 115 - won't go over 2500 RPMS - HELP!!

SparkieBoat, thank you for the help. I see you are familiar with this motor from your other posts. Any more help from you or anyone else would be greatly appreciated! Thanks again and in advance.

 

[Faztbullet]

Re: 1996 Johnson 115 - won't go over 2500 RPMS - HELP!!

First fix your carbs as fuel leaking/flooding is damaging to you and engine. They are leaking from eitheir bad/damaged inlet needles,improper float level or ethanol damaged floats. 2nd get some fresh fuel in tank and proper plugs Champion QL82YC not the 78YC series. You could be picking up RF interference and engine going into SLOW mode(safety feature) or shorted temps sensor or defective pack.

 

[emdsapmgr]

Re: 1996 Johnson 115 - won't go over 2500 RPMS - HELP!!

OMC made two completely different 115 engines in 1996. One is a crossflow, the other is a looper. Pls let us know what the model number is on your engine.

 

[fishe]

Re: 1996 Johnson 115 - won't go over 2500 RPMS - HELP!!

First fix your carbs as fuel leaking/flooding is damaging to you and engine. They are leaking from eitheir bad/damaged inlet needles,improper float level or ethanol damaged floats. 2nd get some fresh fuel in tank and proper plugs Champion QL82YC not the 78YC series. You could be picking up RF interference and engine going into SLOW mode(safety feature) or shorted temps sensor or defective pack.

Thank you Fazbullet, much appreciated. Why the Champion Ql82YC and not the 78YC? They had the 78YC in them for a long time and that is what the book says to put in there? I should have done that but took advice from an advanced auto part genious. Let me know, i'd like to purchase them today. Thanks again.

 

[fishe]

Re: 1996 Johnson 115 - won't go over 2500 RPMS - HELP!!

OMC made two completely different 115 engines in 1996. One is a crossflow, the other is a looper. Pls let us know what the model number is on your engine.

Mine is definitley the looper. J115Sleder. Is the 60 degree. Thanks for your interest. I'll be watching for any help you can provide! What a great forum...

 

[SparkieBoat]

Re: 1996 Johnson 115 - won't go over 2500 RPMS - HELP!!

you need to do the already mentioned things before we can help you any more...once the carbs are repaired and the over heat alarm tested, and the fuel pump tested, and go ahead and check engine compression and do a spark test with a spark gap tester..then run engine with fresh fuel and test while pumping the bulb..

 

[CharlieB]

Re: 1996 Johnson 115 - won't go over 2500 RPMS - HELP!!

took advice from an advanced auto part genious.

Most 'auto parts' people haven't got a clue about any outboard.

Consider the FACTORY Service Manual your Bible. Period.

And do not waste your time or money on any of the aftermarket manuals with the exception of the free CDI Electronics Igntion Troubleshooting Manual. It is possibly the BEST, if not, it is at least 2nd.

 

[SparkieBoat]

Re: 1996 Johnson 115 - won't go over 2500 RPMS - HELP!!

CDI has done a lot to earn my business...their free flow charts are really great..and they will help you over the phone if you have questions..

 

[fishe]

Re: 1996 Johnson 115 - won't go over 2500 RPMS - HELP!!

Ok, did the things I know how to do.

all carbs are new. Right bottom was leaking gas, took out top right and bottom right, cleaned those two again. Installed them.

Took out NGK spark plugs recommended by the advanced auto parts genious, put in new champions per the service manual.

Syphoned old gas out today, put in 5 gallons of fresh, drove around on the trailer for awhile, then syphoned out the 5 gallons so the tank was empty. Put fresh fuel in.

Replaced fuel hose and bulb from fuel/water seperator to motor. Was 5/16 and I went with 3/8, seemed like the right thing to do.

No luck with any of these things, the motor is still performing the way it was prior to me doing these steps. When I got back it was still leaking fuel inside the motor. This has got to be a big part of my problem. Second to that, I took at the new spark plugs to look at all of them. 3 out of the 4 were dark at the top moving down to the the first couple threads. The one that was not looked like it was new from the box. I attached a pic of one of the three that were dark. Don't know what this means. Sounds like I still need to do the following?
-test over heat alarm - don't know how to do this..
-check fuel pump - don't know how to do this..
-check compression - don't know how to do this..
-check spark with gap tester - don't know how to do this..

I will purchase the manual described, I had one (won't mention the name) but have not yet referenced it due to the advice received. Any help with the forementioned would be greatly appreciated. Thanks to all that helped me get the gas out of the boat too, I'm a pro at it now..

 

[SparkieBoat]

Re: 1996 Johnson 115 - won't go over 2500 RPMS - HELP!!

first thing you MUST do is find and fix the fuel leak...it appears that you may have a bad coil/plug wire with that new plug..or you are getting no fuel to that cylinder...after you fix the fuel leak..get a spark gap tester from an auto parts store, remove all plugs and connect the gap tester set at 7/16 gap to plug wires one at the time and turn motor over, you should see a strong blue spark on each cylinder wire. then you test fuel pump by disconnecting the fuel hose coming OUT of the pump going to the carbs..get a small fuel resistant container and pump the bulb till fuel comes out, remove the kill switch key, then have someone turn the engine over and it should shoot fuel out in fairly strong pulses...but if pumping your bulb today did not help we might rule out your fuel pump, so long as that is not where your leak is...fix the leak

 

[boobie]

Re: 1996 Johnson 115 - won't go over 2500 RPMS - HELP!!

Are your float bowls leaking from being warped??

 

[fishe]

Re: 1996 Johnson 115 - won't go over 2500 RPMS - HELP!!

Don't know if float bowls are warped. They don't look like it. how do i tell?

I agree, the fuel leak is priority at this point. The motor did have a little better performance today while pumping the bulb but it was shortlived. It also feels like there is no pressure in the bulb when I pump it, it never gets hard. I imagine this is from the fuel leak in the motor somewhere. I am lost with this leak. New carb kits all over, cleaned all of them at least once...

I'll have to get into it more next weekend.

 

[fishe]

Re: 1996 Johnson 115 - won't go over 2500 RPMS - HELP!!

I forgot, $240.00 so far.

 

[SparkieBoat]

Re: 1996 Johnson 115 - won't go over 2500 RPMS - HELP!!

tilt the motor up some so that the carbs are pointing downward..this may help find your leak

 

[bob johnson]

Re: 1996 Johnson 115 - won't go over 2500 RPMS - HELP!!

I have the 1995 model of that motor and my book says QL77JC4 for the plugs

I always wonder what people really do when they "REBUILD" their carbs??

take them apart, clean a little and reassemble??

or do they use a carb kit?

do they set their float properly to specs set forth by the manual??? for float height and fall...are they taking the whole carb apart and blowing out all the passages???

I have also had a lot of leaking fuel issues with my carbs...i am sure most of it was the brass ball that plugs a hole in the side... plus i get some leaking when i tilt my motor!!!

there are LOTS of gas line connections in that mess....under the airbox and all around the fuel bracket.....many connections have 0-rings right under the brass nipples. basically LOTS of places to leak gas...

the 2500 rpm limit makes the SLOW suspect...the motor runs rough.... i had mine engage once and it felt like the prop had only one blade!!!! vibrated like crazy...but it was the SLOW system taking out some of the spark. normally all you need to dissengage the SLOW system is to have the temp fall below 207* and turn the ignition key off...then the system resets itself USUALLY.

good luck


bob

 

[DargelJohn]

Re: 1996 Johnson 115 - won't go over 2500 RPMS - HELP!!

Does this motor have the OIS ignition system? I have heard similar complaints when the OIS malfunctions.