1999 Johnson 35 hp problems

[Blujay96]

My 99 Johnson 35 hp keeps having problems. Yesterday I went out got it off the trailer and it started up great ran it across the lake and anchored. When we went to go it started stuttering. After it sat for a little bit it would start up but would not stay running. Hear is a list of what has been done. Power pack replaced, fresh fuel put in, seafoam. I am going to change the fuel filter. Is there anything else I should check.

 

[pn]

Re: 1999 Johnson 35 hp problems

fuel pump.clean carbs, fuel obstructions, clogged vent.

 

[Blujay96]

Re: 1999 Johnson 35 hp problems

Ok I changed the fuel filter. When it's at idle in getting a burst of air and smoke from somewhere on the motor. Looks like around the middle cylinder from the port side. Does it about every 45-80 seconds. Hoping there is nothing major wrong with it.

 

[Blujay96]

Re: 1999 Johnson 35 hp problems now with vids

Re: 1999 Johnson 35 hp problems now with vids

This first vid is idling when warming up.
Motor 6 - YouTube

This is after it warms up for a while.
Motor 9 - YouTube

This is trying to start after it dies.
Motor 10 - YouTube

This is after waiting for about 15 mins. Plus pushing in the key to keep it running.
Motor after sitting 15 mins - YouTube

 

[hidef]

Re: 1999 Johnson 35 hp problems

First of all git rid of the oil tank and mixing chamber and premix your gasoline at 50:1. The OMS system is very prone to failure.

For the starting issues when hot unplug the the two yellow wires going to the regulator / rectifier for the stator it is behind the black plastic air intake. See if that helps a bad regulator can cause the symptoms you are experiencing.

 

[Blujay96]

Re: 1999 Johnson 35 hp problems

Is there a procedure for taking the oil pump off.

 

[hidef]

Re: 1999 Johnson 35 hp problems

Disconnect the wiring and unbolt the tank. and remove. Connect the fuel line that currently runs from the tank/mixing chamber to the carbs on the port side of the engine directly to the fuel filter discarding the short piece of fuel hose that currently connects the mixing chamber to the fuel filter. Then secure the connector that was connected to the oil tank out of the way. The alarms system works when a connection is closed so with the connector unplugged the alarm system for low oil / no oil will never go off.

 

[Blujay96]

Re: 1999 Johnson 35 hp problems

Thanks for the help I will report back when done

 

[Blujay96]

Re: 1999 Johnson 35 hp problems

Ok removed the oil injection. Mixed the gas 50:1. Also found a couple small hoses that were off and needed replaced. They were on the port side of the motor near the cylinders. Not sure what they do. It started right up and ran for about 5 mins. Then it would not start back up. Tried unplugging the two yellow wires no change. I'm going to wait a little bit and try to start it again. Any thoughts.

 

[Blujay96]

Re: 1999 Johnson 35 hp problems

Oh and I checked the pick up line and vent on the tank.

 

[hidef]

Re: 1999 Johnson 35 hp problems

What hoses can you post a photo?

 

[Blujay96]

Re: 1999 Johnson 35 hp problems



And I just found these cracks

 

[hidef]

Re: 1999 Johnson 35 hp problems

The black hoses are for recirculation and should hooked up. The small green ones are for the primer. It looks like it is the paint that is cracked the metal there is pretty thick.

 

[Blujay96]

Re: 1999 Johnson 35 hp problems

I took a small screw driver and it chipped right off. Metal looks good behind it.

 

[Blujay96]

Re: 1999 Johnson 35 hp problems

Still can't get it to fire back up after it has ran for a little while. ????

 

[hidef]

Re: 1999 Johnson 35 hp problems

Was the power pack you swapped out new or used? Have checked all of your connections?

 

[Blujay96]

Re: 1999 Johnson 35 hp problems

Power pack was replaced by the dealer I bought the pontoon from. It was new according to them. I have check all the connections. I will check again

 

[Blujay96]

Re: 1999 Johnson 35 hp problems

Connections look good

 

[hidef]

Re: 1999 Johnson 35 hp problems

Did you pull the screens off the fuel pumps and clean those? I don't think it fuel related because in your video when the engine is hot it sounds like it isn't firing. Which would make it electrical. You can try following the CDI guide for troubleshooting start on page 61 use the instructions for V4 or V6 with optical ignition as that is what the compact triples use. There is no write up in the guide for them. The link is in my sig.

 

[Blujay96]

Re: 1999 Johnson 35 hp problems

Screens were clean. Checked all the ground connections. Found a small crack on the primer bulb. Doesn't look like it goes all the way thru. Going to replace that just in case. Cut the yellow black wire still no change. Cleaned all the connections on the coils. Still can't get it to run more than a minute or so. Took it to a marina and spent 200 dollars for them to look at it. They put a impeller and a thermostat in. They said it was good to go. Got it home and no change. (Not happy about that). What would be my next step.