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Old 07-25-2007, 10:02 AM
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Default Johnson oceanrunner problems?

I have a 1998 Johnson Oceanrunner 200 HP motor that I am having a few problems with. The last time I was out, I noticed that it was struggling to plane off. Once it did plane off, it seemed to run fine. But, getting on plane was a struggle. It would idle fine and all. Then the next day when I went to start it off the hose to flush it, it did not want to idle right and kept shutting off. When it was running I noticed that it was not loud as usual like it was not hitting on all cylinders. Even when I reved it up some it was not running as loud and deep sounding as usual. I tried an easy fix of changing plugs and the same thing happened. After I shut it off, I noticed some nasty grey ooze coming out of the prop exhaust. I know this is alot of symptoms to diagnose, but, I would appreciate any ideas on the culprit. I have made a call to get on a local mechanics waiting list, but was wondering if anyone here might have some ideas.
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Old 07-25-2007, 12:02 PM
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Default Re: Johnson oceanrunner problems?

It sounds like you may have a cyl or 2 that are not firing. I would check the spark at each plug and I'd bet you have two which are not firing and need a new power pack. The gray looking stuff is unburned fuel/oil which is coming from the cyl. which are not firing. I'm no mech. by no means but I think that you will find that if one is not firing on one side you will find the other across from it not firing which both work off the same power pack. I check spark by starting the motor and removing each plug wire with a insulated pair of pliers and look for a spark jumping from the wire to the plug. If its sparking you will notice it getting worse and if it is not sparking the engine will sound the same.
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Old 07-25-2007, 12:18 PM
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Default RE: Johnson oceanrunner problems?

First thing to check is the shift interrupt switch it is under the powerhead you will see where the shift cable makes contact with it,they will stick over time.If it is your pack,make sure you check the stator,as this is the culprit for alot of pack failures.Another thing to keep an eye on are the magnets inside the flywheel they break loose and will advance the timing to a point that you will burn a hole in the piston.
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Old 07-25-2007, 12:19 PM
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Default Re: Johnson oceanrunner problems?

I have a 2000 200hp Johnson that was having similar problems to yours and as fishingfun stated, it was the power pack. I had my mechanic diagnose my engine, but the method fishingfun mentioned should work to give you an idea if the power pack is the cause.
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Old 07-25-2007, 03:01 PM
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Default RE: Johnson oceanrunner problems?

I just replaced my power pack AND shift interruptor switch on my Johnson 200 HP Ocean Runner.
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Old 07-25-2007, 10:22 PM
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Default RE: Johnson oceanrunner problems?

Thanks for the tips. Is there only one power pack on this motor? Any idea what a power pack cost? I had a problem with a cylinder not firing a couple of years ago and someone let me borrow some kind of spark gap tester. I have not been able to find one anywhere. You would hook the wire to it and then screw it in or out to set the correct gap and then try to start it to see if the spark was making the gap. I would like to find another one of those testers somewhere. That particular time it was corrosion on one of the connectors. But, I would believe with the way it sounds now it would have to be more than one cylinder not firing. Plus the grey muck coming out of the exhaust. I appreciate the info and will give the checks mentioned a shot. This site has always steered me in the right direction.
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Old 07-26-2007, 09:54 PM
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Default RE: Johnson oceanrunner problems?

bump
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Old 07-26-2007, 10:38 PM
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Default RE: Johnson oceanrunner problems?

Yes, one power pack. It's not that expensive to replace. I can't remember exactly how much when I replaced mine, but I didn't get sick over it.
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Old 08-07-2007, 05:01 PM
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Default RE: Johnson oceanrunner problems?

Well, I have finally got around to checking on the engine again. I checked for spark on the cylinders and found three of the six not firing. When I am standing at the back of the motor the right side top to bottom are not firing. Does this sound like the power pack? Any other checks to be sure that the culprit is the power pack? Thanks for any info.
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Old 08-07-2007, 05:23 PM
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Default RE: Johnson oceanrunner problems?

Quote:
brdf - 8/7/2007 5:01 PM

Well, I have finally got around to checking on the engine again. I checked for spark on the cylinders and found three of the six not firing. When I am standing at the back of the motor the right side top to bottom are not firing. Does this sound like the power pack? Any other checks to be sure that the culprit is the power pack? Thanks for any info.
I think if it is one whole side that is not a power pack problem. If I'm correct if it was a power pack it would be like the top left and right plug or the middle left and right plug but not one whole side as they use seperate power packs. I could be totaly wrong and I'm sure some could confirm this. Do you have a manual? If so find this section and it should tell you what to check if one whole side is gone. I have a manual at home but I'm not sure if it covers this year and size that you have but I will check.
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Old 08-07-2007, 05:41 PM
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Default Re: Johnson oceanrunner problems?

IMHO that is the SHIFT INTERUPT switch that is sticking, as it kills one bank when shiftinb between Neutral and Forward. Note for trivia sake, it is more for shifting from Forward and back to Neutral, as otherwise there is soooooooooooooo much torque (from being 'in' gear) that the gears would want to stay meshed or engaged.

I had mine stick once and the previous owner apparently sprayed everything with Boeshield T9. Now this is why I no longer recommend Boeshield T9 on any MOVING part ... as it will gum up in the future and cause sticking problems like this. I'd drop the starboard side cowling and pull the switch out of its mounting bracket and spray it up good. Also make sure it is not cracked, as it will tilt instead of actuate.
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Old 08-07-2007, 07:38 PM
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Default RE: Johnson oceanrunner problems?

Thanks for the tips. I located the shift interupt switch and will pull it tommorow to see if it is sticking. Someone on another board mentioned a temp sender on the port side which will kill the spark to half the cylinders. Anyone have any information on this as to where it is and how to check it? Thanks for any info.
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Old 08-08-2007, 04:27 AM
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Default RE: Johnson oceanrunner problems?

Quote:
brdf - 8/7/2007 7:38 PM

Thanks for the tips. I located the shift interupt switch and will pull it tommorow to see if it is sticking. Someone on another board mentioned a temp sender on the port side which will kill the spark to half the cylinders. Anyone have any information on this as to where it is and how to check it? Thanks for any info.
I second the shift interupt, I had to replace one on one of my motors. Take it off and check it with an ohm meter, open and close it while checking it for continuity. Mine was working intermittenly. I think it was about $60 from the dealer, if you have any doubts about it I would just change it.
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Old 08-08-2007, 08:23 AM
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Default Re: Johnson oceanrunner problems?

I also had a problem with interupt switch on a 97 175 hp Oceanrunner.
It was intermittant and took awhile to figure out, but once changed the
motor worked fine. Only issue I had with it other than it's very thirsty.
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Old 08-08-2007, 08:41 AM
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Default RE: Johnson oceanrunner problems?

Quote:
brdf - 8/7/2007 6:38 PM
Someone on another board mentioned a temp sender on the port side which will kill the spark to half the cylinders. Anyone have any information on this as to where it is and how to check it? Thanks for any info.
Sure, but ... it doesn't kill the bank (that I know of) what an overheat alarm does is trigger the powerpack to INTENTIONALLY mess up the timing so she won't run over 2,000 to 2,500 RPMs and she'll shake soooooooooooo bad like Courtney Love coming off a high. The shakin and mis-timing is to prevent you from daring to push the throttle ... believe me - it works! OMC called this mode "SLOW" for Speed Limiting Overheat Warning.

There's an overheat sensor on top of each bank up by the thermostat housing. Look for a single-wire TAN lead that goes to a pull-apart connection. Have a small piece of 14/16 AWG wire handy, stripped on each end. Turn your ignition ON but don't start the motor, pull apart the connection and insert that test wire into the female bullet connector (side closest to the head) and ground out the other end to the block. You should hear the alarm sound. That means the sensor is OK.

Now that tan alarm sensor that triggers the SLOW mode also is the same alarm code for vacuum or lean burn conditions, and there is a blocking diode in the harness that prevents the SLOW mode from being activiated when triggerred solely by the vaccuum switch. But don't let you worry you, I'm 99% confident via cyberspace diagnosis that you have a sticky or faulty shift interrupt switch.

Cheers and good luck! Please LET US KNOW how you make out and the resolution, as that preserves the integrity of the THT archives.
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Old 08-08-2007, 08:50 AM
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Default Re: Johnson oceanrunner problems?

Power Pack
Switch the plug wires and see if the non firing cylinders moves w/ the wire movement
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Old 08-08-2007, 09:23 AM
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Default Re: Johnson oceanrunner problems?

I'm a little late jumping in here. I had power pack problems last year on the same motor. They cost about $180 at West Marine. A little less elsewhere if you find one in stock. (I bought a Sierra brand) Pretty easy to install.

Here's some info my outboard mechanic gave me:

1 Bad cylinder = bad coil
1 Bad Cylinder on each side = Bad Timer Base
Loss of all cylinders on one side = Bad Power Pack

My problem was intermittent and it was hard to catch it happening on the hose to figure out what was happening. I just guessed at the Pack and got it right.
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Old 08-08-2007, 09:45 AM
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Default Re: Johnson oceanrunner problems?

Check the interupt switch first, it kills the 3 starboard cyls. You can probably follow the wire from the switch and unplug it then crank the motor and see if you have spark on the starboard cyls.
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Old 08-08-2007, 06:37 PM
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Default RE: Johnson oceanrunner problems?

Thanks again for all the information. I think we have found the culprit. I made some more checks today and I unplugged the shift interupter switch and tested again for spark on the starboard cylinders. All cylinders are now sparking a good blue spark. I pulled the switch off and it appears to be stuck in the down position. I tried to clean it and get it to free up with no luck. I am going to make some calls and try to find one locally and be back up and running by the weekend.
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