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2005 Johnson - Help

Old 10-11-2020, 12:07 PM
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Default 2005 Johnson - Help

I have a 2005 Johnson 115 2 stroke carbureted motor that I could use some help diagnosing. All the shops in my area are backlogged for weeks.

I have had 15 yrs of trouble free use. Good compressions, new plugs, fresh rebuilds on carbs.

Sometime when I try to do a hole shot, it will just bog down and die. Other times it will launch off as it should. I know the idle seems to be set to low, about 350 - 400 rpm. I believe the idle timing is at 3 degrees after top dead center.

ideas?
Old 10-11-2020, 01:34 PM
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Push the key in while it bogs. That activates the primer which gives the engine extra fuel. If it picks up you know she is starving for fuel.
Old 10-11-2020, 01:40 PM
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I have the same exact problem with my 2005 90 Johnson two-stroke. Pushing in the key activates the primer solenoid and that makes my engine pick up from bogging. Mine does it intermittently. I can tell right away when I start the motor whether it's going to be a problem, I can hear it. I've also lost about 800rpms at the top end, won't go above 4800rpms this season. Something's up. Could be more than one issue.

Super frustrating. I'm at my limit working on it myself - the carbs were all rebuilt last year, whole fuel system has been gone through, etc. Waiting for my local place to be able to take a look when the season is over here in a few weeks. They have been really backed up as well. I'm sure it's something simple but I just don't want to deal with it myself anymore.



Old 10-11-2020, 01:48 PM
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Replace plugs with correct Champion plugs, check spark on all cylinders, do a compression test, clean carbs properly, do a link and sync as per your manual, go boating.
Old 10-11-2020, 05:56 PM
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Originally Posted by noelm View Post
Replace plugs with correct Champion plugs, check spark on all cylinders, do a compression test, clean carbs properly, do a link and sync as per your manual, go boating.
good thoughts but have done all those steps except, testing the spark. and still have the issue. Runs like a champ when it does get on plane. 5400 RPM. idle timing set at 3 ATDC full throttle timing set at 20 BTDC. Wondering if maybe the fuel pump may be acting up?
Old 10-11-2020, 06:14 PM
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Did you just clean the carbs "properly" or are you still relying on them being rebuilt ages ago? did you use Champion plugs?
Old 10-11-2020, 06:35 PM
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Originally Posted by noelm View Post
Did you just clean the carbs "properly" or are you still relying on them being rebuilt ages ago? did you use Champion plugs?
I rebuilt them with new OMC carb kits last month. New needle, seat, float, seals, etc. all by the Shop manual. Set the float drop range, set the mixtures at 6 turns out from bottom.
Old 10-11-2020, 06:36 PM
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New parts are nice, but did you clean them? not washed, sprayed or soaked.....
Old 10-11-2020, 07:09 PM
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Originally Posted by noelm View Post
New parts are nice, but did you clean them? not washed, sprayed or soaked.....
The parts that were reused were soaked in mineral spirits. Then compressed air, then sprayed with carb cleaner, then more compressed air, then assembled with the new parts. As best I can tell they were well cleaned. Given they are partially plastic, I did not want to get crazy with powerfull solvents.

I am not a boat mechanic but have a lot of experience with cars and aircraft with carbureted engines. Additionally, due to time off due to COVID, I did the same rebuilds on my 2005 Johnson 175 ( same motor but 2 more jugs) and not had any issues with that one.

I thought I was doing a good thing to get both my boats all tuned up but the 115 is so far kicking my butt to get it just right.

i used the OMC timing box or whatever you call it, while checking the linkage and timing per the shop manual. This is the box that plugs into the optical sensor . . . . .

i assume I am missing something simple.

Last edited by OldBob; 10-11-2020 at 07:15 PM.
Old 10-11-2020, 08:19 PM
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OK, all the carb parts now look pretty, but it's unknown if all the jets and passages are clear/cleaned, are the fuel bowls warped? If you have been playing around with the optical ignition, that is now suspect too.
Old 10-12-2020, 02:46 AM
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Have you tried a clean external fuel tank?
Old 10-12-2020, 07:18 AM
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Originally Posted by Mangimi View Post
Have you tried a clean external fuel tank?
I had not thought of that, I will jive it a try, thanks for the ideas. It does have a Yamaha screw-on canister fuel filter that I did replace.
Old 10-12-2020, 07:42 AM
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I’d look at the fuel bulb and lines in way of it also.

My 2004 90 Johnson would bog down at high speed. Took fuel line off and found inside lining collapsing. Replaced and she runs great again.

Good luck.
Old 10-12-2020, 08:17 AM
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In trying to get my 200 Ocean Runner working correctly I bought an index pack of these small plastic clamps and replaced all of the hodge podge of spring clamps, hose clamps and tie wraps on my engine and fuel system lines. I also replaced all fuel lines from the tank to the engine (23 years old and all original).. Last week while doing a Seafoam shock treatment I noticed bubbling coming out of a recirculation hose. so tested the recirc check valves (all good), and then pulled recirc hoses, wire brushed the nipples sprayed off with carb cleaner and re-attaced with the small sized plastic clamps. The combination of all my efforts has resulted in the engine running much better although since I did a bunch of lines at the same time I cannot say with any certainty exactly which line may have been the leaker.


Old 10-12-2020, 03:19 PM
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Originally Posted by noelm View Post
OK, all the carb parts now look pretty, but it's unknown if all the jets and passages are clear/cleaned, are the fuel bowls warped? If you have been playing around with the optical ignition, that is now suspect too.
fuel bowls are not warped, all jets and passages clean, each carb set a 6 turns, no work on ignition system work other than new champion plugs and the timing set with OMC 43401 ignition analyzer

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