MichaelServetus
New member
Hey everyone. I apologize for the long post, but I've made some mistakes and I am running out of ideas on how to fix them.
To start off, I am a boating novice who purchased a 14' craft with a two-stroke '93 Johnson 60. I taught history and coached, so one of my former students wanted to work on the engine. I wanted to help the former student and if I was going to pay anyone, why not him? The student was a technician and also worked on fishing charters, so I figured they knew what they were doing. After rerouting the wiring to my console and away from the control box, and a litany of other modifications, everything went wrong. The boat would crank, it would run beautifully, and then go into limp mode whenever I ran the boat above 2,500 RPM's for longer than a few minutes. I should have gone to a professional with anything I wanted to do.
After taking it to a respected mechanic, who claimed to fix the problem, but never water tested the boat (the boat went RIGHT back into limp mode), I went to a different mechanic. Now, the boat starts at the first crank, runs beautifully, and after two minutes under load at over 2,500 RPM's, it goes into limp mode. After trying several fixes and the problem persisting, we disconnected the overheat sensor and ran the boat at over 2,500 RPM's for 10+ minutes. We were comfortable putting that strain without the overheat sensor attached because...
We have:
-Rerouted the wiring BACK to the control box and undone the electrical mess
-Cleaned the carbs with new gaskets
-Rebuilt/Replaced the water pump
-Replaced overheat sensor
-Replaced the stator
-New coils, wires, and plugs
-New oil pump
-Cleaned and gotten rid of any leaks in the fuel lines
The next step were going to try is to replace the CDI box, as it had been rigged by my former student. The student had jumped off the battery multiple times from a running car, and we are not sure it was done right from the beginning. The mechanic I am working with now is borrowing a working CDI box from another Johnson 60 of the same year and we are going to see if switching them out fixes the problem.
Does anyone have any other ideas?
To start off, I am a boating novice who purchased a 14' craft with a two-stroke '93 Johnson 60. I taught history and coached, so one of my former students wanted to work on the engine. I wanted to help the former student and if I was going to pay anyone, why not him? The student was a technician and also worked on fishing charters, so I figured they knew what they were doing. After rerouting the wiring to my console and away from the control box, and a litany of other modifications, everything went wrong. The boat would crank, it would run beautifully, and then go into limp mode whenever I ran the boat above 2,500 RPM's for longer than a few minutes. I should have gone to a professional with anything I wanted to do.
After taking it to a respected mechanic, who claimed to fix the problem, but never water tested the boat (the boat went RIGHT back into limp mode), I went to a different mechanic. Now, the boat starts at the first crank, runs beautifully, and after two minutes under load at over 2,500 RPM's, it goes into limp mode. After trying several fixes and the problem persisting, we disconnected the overheat sensor and ran the boat at over 2,500 RPM's for 10+ minutes. We were comfortable putting that strain without the overheat sensor attached because...
We have:
-Rerouted the wiring BACK to the control box and undone the electrical mess
-Cleaned the carbs with new gaskets
-Rebuilt/Replaced the water pump
-Replaced overheat sensor
-Replaced the stator
-New coils, wires, and plugs
-New oil pump
-Cleaned and gotten rid of any leaks in the fuel lines
The next step were going to try is to replace the CDI box, as it had been rigged by my former student. The student had jumped off the battery multiple times from a running car, and we are not sure it was done right from the beginning. The mechanic I am working with now is borrowing a working CDI box from another Johnson 60 of the same year and we are going to see if switching them out fixes the problem.
Does anyone have any other ideas?