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2000 Johnson surges at high speeds

M

markd

New member
"Hi, new to posting, been read

"Hi, new to posting, been reading for a while, great info, thanks. My problem is my engine surges at WOT and looses power. Last year ran out of gas, problem started. Like to fix it now. Flushed out gas tank, totally cleaned, new fuel line to engine and water separating system installed. Engine idles good. At WOT the Prime bulb goes spongy/soft and does not want to pump back up when surging starts. OK I tried prior to engine fix so possibly dirt/junk in carb where? float chamber vent? Plugged High speed orifice? Don't really know where the are located just picked it up from a manual. Looking for an easy fix if it's possible, sure could use some advice."
 
Couple of things come to mind.

Couple of things come to mind..carbs for sure as you mentioned a new water filter was installed after you ran the tank dry...no protection from the crud in the tank prior! Also check the tank vents...if they are partially plugged the fuel pump will struggle to suck fuel...more so at wot when demand is at the highest. Could be why the primer bulb goes flat at wot.
 
"Hi there, finally got a chanc

"Hi there, finally got a chance to work on my 2000 115VLSS Johnson. Tank vents clear,also plenty of carb cleaner sprayed directly into running engine via carbs, fuel pick-up had clean screen on it and cone screen post VRO unit on engine cleaned. Beebee knocked out of the anti-syphone valve. Now the bulb is no longer spongy and pumps up hard. As I remember last season: 1)ran out of gas. 2)Got 15 gallons the engine ran good approx 8 miles. 3) next day boat ran good all day but, on the way back in engine started to surge and sputter at WOT. Now after all these successful failures It possible is something else. Years ago on another boat with a 90hp Johnson same surge then eventually just sputtering at WOT it turned out to be the stator I think? Could this be possible ? Is their a test I could do without at test tank."
 
"next step...would be to do a

"next step...would be to do a fuel pressure test to carbs,....and to ck for air entering fuel line....if fuel pressure is good to carbs,then i would at least eliminate carb probs,by cleaning and rebuilding them....running lean on these is not good......can u pump primer bulb,when it surges,see if that helps...a clogged pulse limiter will do that,as well as a failing vro(oms) pump."
 
I pumped the primer bub while

I pumped the primer bub while WOT no changes engine continued to sputter. And also tried leaving the gas cap open no difference.
 
"well,..before going any furth

"well,..before going any furthur,...i would suggest doing a comp and spark test...to eliminate major probs..."
 
My tachometer reads 1500 and d

My tachometer reads 1500 and doesnt move now is this something with the pulse limiter. Just shooting in the dark.
 
"no,..the pulse limiter,is bas

"no,..the pulse limiter,is basically a backfire valve to protect the vro,on the pulse line...i will post a diagram,so u know what these items are....your tach prob......is another issue."
 
"u need a factory service manu

"u need a factory service manual,to properly service/diagnose your eng.here is the diagram..
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"# Part # Description Qty Req&

"# Part # Description Qty Req'd Price Availability Order Qty
# Part # Description Qty Req'd Price Availability Order Qty
1 0339603 HOSE, oil inlet. See Accessories Part Catalog for repair kit P/N 1 $4.79 USD Available
2 0438400 FUEL PUMP ASSY. - Z 1 $398.00 USD Available
3 0512749 *CONNECTOR 1 $7.78 USD Available
4 0581656 *SOCKET 4 $1.96 USD Available
5 0435009 *PULSE LIMITER 1 $27.73 USD Available
6 0124549 *SCREW, Retainer 2 $2.68 USD Available
7 0125203 *O-RING, Pulse fitting 1 $3.13 USD Available
8 0125212 *SCREW, Pulse fitting retainer 2 $1.10 USD Available
9 0339276 *CLAMP 2 $0.27 USD Available
10 0340201 *RETAINER, Pulse fitting 1 $3.81 USD Available
11 0343172 *RETAINER, Outlet fitting 1 $3.09 USD Available
12 0345239 *FITTING, Outlet 1 $4.82 USD Available
13 0340200 *FITTING, Pulse 1 $3.28 USD Available
14 0335230 *O-RING, Fuel pump to bracket 3 $3.19 USD Available
0437778 VAPOR SEPARATOR 1 $159.18 USD Available
15 0340082 *BRACKET, Fuel components 1 $32.20 USD Available
16 0124369 *O-RING, Filter to vapor separator 1 $4.30 USD Available
17 0396521 *FLOAT VALVE AY., Vapor separator 1 $6.52 USD Available
18 0336842 **SPRING CLIP 1 $1.07 USD Available
19 0331365 *O-RING, Vapor sep. nipple to brkt. 1 $2.97 USD Available
20 0327270 *GASKET, Fuel filter 1 $3.95 USD Available
21 0331365 *O-RING, Vapor separator 1 $2.97 USD Available
22 0326164 *SCREW, Hinge pin to separator 1 $3.73 USD Available
23 0335112 *NUT, Fuel filter 1 $5.25 USD Available
24 0336650 *PIN, Vapor float assy. 1 $3.03 USD Available
25 0340083 *NIPPLE, Vapor separator outlet 1 $3.81 USD Available
26 0335385 *COVER, Vapor separator 1 $40.24 USD Available
27 0335236 *SEAL, Vapor separator to bracket 1 $7.93 USD Available
28 0433190 *FUEL FILTER ASSY. 1 $12.99 USD Available
29 0305739 *O-RING, Nipple, cover to manifold 2 $1.40 USD Available
30 0343576 *NIPPLE, Fuel outlet 2 $8.45 USD Available
31 0433410 *FLOAT & ARM ASSY., Vapor sep. 1 $16.09 USD Available
32 0328649 *SCREW, Separator to bracket 4 $3.73 USD Available
33 0303630 *WASHER 1 $2.02 USD Available
34 0330057 *SCREW, Plug 1 $2.48 USD Available
35 0315656 *SCREW, Retainer & nipple 2 $3.54 USD Available
36 0335685 *RETAINER, Outlet fitting 1 $3.52 USD Available
37 0433352 PUMP ASSY., Vapor 1 $83.18 USD Limited
38 0331307 DIAPHRAGM, Main 1 $2.02 USD Available
39 0 HOSE, Vapor pump to bearing vent nipple, 15 in. (381mm). Cut to from bulk P/N 340848 1 Not Available
40 0320107 TIE STRAP 1 Dealer Install Only
41 0437232 SOLENOID ASSY., Primer 1 $158.14 USD Available
42 0512947 *TERMINAL, Bullet 1 $0.36 USD Available
43 0513185 *SLEEVE 1 $1.25 USD Available
44 0511809 *PLUNGER 1 $11.47 USD Available
45 0330121 *SCREW, Cover to housing 4 $3.73 USD Available
46 0332365 *FILTER, Valve housing 1 $3.52 USD Available
47 0341297 *GASKET, Housing 1 $8.35 USD Available
48 0333447 *VALVE, Plunger 1 $3.52 USD Available
49 0341071 *COVER, Solenoid 1 $7.99 USD Available
50 0175158 *VALVE ASSY., Maintenance 1 $6.99 USD Limited
50A 0126341 **CAP VALVE 1 $3.52 USD Available
51 0331365 *O-RING, Valve 1 $2.97 USD Available
52 0511986 *SPRING, Valve 1 $3.52 USD Available
53 0511987 *SPRING, Plunger 1 $3.52 USD Available
54 0512876 *TERMINAL, Socket 1 $0.77 USD Available
55 0513186 *SLEEVE 1 $1.88 USD Available
56 0 HOSE, Primer solenoid to stbd. primer nipple, 14 in. (356mm). Cut to from bulk P/N 327229 1 Not Available
57 0513816 SLEEVE, Pulse hose 1 $0.72 USD Available
58 0334131 HOSE, Pulse 1 $9.30 USD Available
59 0332437 O-RING, Vapor pump to sep. cover 1 $1.02 USD Available
60 0339688 HOSE, Vapor sep. to pump assy. 1 $4.79 USD Available
61 0335626 NIPPLE, Fuel & oil 1 $13.57 USD Limited
62 0315391 PLUG, Connector, oil 1 $0.60 USD Available
63 0331649 PLUG, Connector, fuel 1 $0.56 USD Available
64 0339607 HOSE, Bracket to port manifold 1 $5.79 USD Available
65 0335229 SCREW, Vapor pump to cover 2 $3.73 USD Available
66 0339278 CLAMP, Wire 2 $0.42 USD Available
67 0512743 RETAINER, Connector 1 $3.99 USD Available
68 0123112 CLAMP, Oil tank hose 1 $1.99 USD Available
69 0339277 CLAMP, Wire, oil hose 2 $0.27 USD Available
70 0325402 SCREW, Bracket to c'case cover 4 $2.33 USD Available
71 0336316 WASHER, Screw, bracket to cover 4 $3.59 USD Available
72 0335231 O-RING, Primer solenoid to bracket 2 $3.19 USD Available
73 0329653 CLAMP 1 Dealer Install Only
74 0322654 CLAMP 1 Dealer Install Only
75 0 HOSE, Vapor pump to tee, 7 in. (178mm). Cut to from bulk P/N 335738 1 Not Available
76 0329661 PLUG / HOLDER 1 $3.52 USD Available
77 0336318 HOSE, Pulse, vapor pump to c'case cover 1 $3.75 USD Available
78 0339279 CLAMP, Wire 4 $0.42 USD Available
79 0 HOSE, Primer solenoid to port primer nipples, 12 in. (305mm). Cut to from bulk P/N 327229 1 Not Available
80 0315656 SCREW, Primer solenoid to bracket 2 $3.54 USD Available
81 0339604 HOSE, Fuel connector to filter 1 $6.38 USD Available
82 0328649 SCREW, Pump to bracket 3 $3.73 USD Available
83 0339606 HOSE, Bracket to stbd. manifold 1 $5.56 USD Available
84 0328735 WASHER, Screw, pump to bracket 3 $3.59 USD Available
85 0329518 GROMMET, Bracket to powerhead 4 $3.06 USD Available"
 
Compression test 150psi all 4

Compression test 150psi all 4 cylinders and all 4 cylinder are getting spark thank God for both
 
"great........back to fuel del

"great........back to fuel delivery....carbs first..make sure to inst new kits,all jets,orifices,must be clean/open...thses r plastic carbs,no strong carb cleaner.....seafoam,deepcreep,de-carboner etc to disolve gunk in bowls.rinse w/water after,..blow dry,..ck all areas w/flashlite,re-assemble."
 
Maybe i overlooked it but he d

Maybe i overlooked it but he doesnt say how strong the spark is.....how much gap will it jump on a tester?did he replace all of his fuel hose or just part of it and what size hose did he use?
 
I don't have a tested for

I don't have a tested for the spark. I held it to the block with the wire on. One of the cylinders had a yellowish spark and the others were blue. Does this mean anything?
 
yes orange/yellow is weak spar

yes orange/yellow is weak spark..........you can make your own spark tester with a board and 2 nails...........you can make it multiple and check all at once--tkaes 5 nails.

all you need to do is connect one nail to the batt with a ground wire and hook the spark plug wire to the other..........set the gap by bending the nails toward each other.

7/16 gap and good blue flame with a snap........careful it will bite you.
 
"Reading through this, it real

"Reading through this, it really looks like the ignition is weak on one plug.
Try swapping coils and wires to see if the problem follows the coil. Look for cracks in the potting plastic on the bottom of the coil.

I have to make me one of them spark testers one day so I can check them all at the same time."
 
"i should have specified that

"i should have specified that you will need a nail for each cyl and one for the ground....however if you have a 8cyl you may want to use 2 grounding nails and 4 plug wires to each ground............i was just assuming your 115 was a 4cyl.....

gerald,
im glad you pointed that out....it never crossed my mind to have him switch coils around."
 
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