2005 Johnson 90hp carburated 2 stroke - warped float bowl repair documentation

SweetD

Petty Officer 2nd Class
Joined
Jan 19, 2010
Messages
153
All,

I get a lot of information from this website and contribute very little. I appreciate the knowledge here. I just wanted to document my successful repair of my leaky carb bowl on my 2005 Johnson 90hp 2 stroke carb'd outboard so someone with the same issue down the road can hopefully find benefit.

Originally I smelled fuel when on my boat at rest. Turned out I had gas pouring out of the bowl on one of my carbs when I pumped the primer bulb. The gasket between the float bowl and the carb body had just blown out.

Long story short the bowl was warped. I went to my trusty marine mechanic in town to order a rebuild kit first, and when that did not solve the problem, I went back to get a bowl. Unfortunately he did not have one in stock and I did order one for future use.

But, this guy is experienced (like many of you) and suggested that I sand the gasket mounting lip on a flat surface to see if I could at least temporarily salvage the warped bowl.

So I took the bowl, and on our bathroom countertop (flat silestone, my wife was not at home) laid a piece of 220 grit sand paper down, and slowly rubbed the gasket mounting surface of the bowl in a circular pattern, checking frequently to see whether the entire "lip" was being sanded. Eventually it was, and I replaced the gasket and re-assembled the carb to the motor.

Worker like a charm - ran the motor for an hour in the Atlantic here in RI and checked afterwards - no leaks!

So hopefully this can help someone suffering from the same affliction to easily find this option for repair...

Thanks!

Dave
 

kodibass

Master Chief Petty Officer
Joined
Apr 10, 2010
Messages
864
Re: 2005 Johnson 90hp carburated 2 stroke - warped float bowl repair documentation

Thanks for sharing I have the plastic bowl problems with the 9.9/15 late 80s all the time, I have been meaning to try this myself. glad to hear of your success.
 
Top