98 Johnson 115 spl water leak

[sw192cc]

I just rebuilt powerhead on my 1998 Johnson 115 spl v4 crosslow. Motor run great but I have a water leak behind the front cowl to exhaust housing cover when the motor is running. After closer inspection I found the water was comming from the area where the 7/16 bolts are that connect the upper exhaust housing to the lower exhaust housing at the front of the outboard where the transom bracket is.
I retorqued the powerhead mounting bolts and don'y believe it is comming from there.
Where is it coming from. I have a factory OMC shop manual for the outboard and don't see how it could be coming from there. I used gasket sealer on the inner and outer exhaust covers and install the powerhead gasket dry as the manual suggested.
Any help would be greatly appreciated.

 

[jeffersondodson561]

Re: 98 Johnson 115 spl water leak

I remember on one occasion, when replacing the exhaust baffles we had to mill down to get the tuner plate to mate up accordingly, this was after we called OMC. OMC is the redheaded stepchild of BRP.

 

[BKS72]

Re: 98 Johnson 115 spl water leak

Powerhead to midsection gasket upside down will cause that leak, too.

 

[sw192cc]

Re: 98 Johnson 115 spl water leak

Thanks for the replies guys, I will check the gasket first... It really surprises me that the manual said to install it dry!

It runs very good other than the leak.
I guess it should... It had broken rings in two cylinders before the rebuild!!!!

 

[DargelJohn]

Re: 98 Johnson 115 spl water leak

Thanks for the replies guys, I will check the gasket first... It really surprises me that the manual said to install it dry!

It runs very good other than the leak.
I guess it should... It had broken rings in two cylinders before the rebuild!!!!

You install it dry so you don't get sealant in the water passage ways. That's a stout gasket, aluminum core, sandwiched between paper. After torquing the bolts/nuts, leave the midsection skirt off, run the motor for the first time, and retorque the bolts/nuts with the engine cold, reinstall skirt.