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    rebuild break-in period

    I'm two hours into the recommended ten hour break-in period on my 40hp Johnson 2 stroke since rebuilding it. I don't have a tach on my engine, so would it be okay to run at wot for a second or two just to see where it is? It's kind of hard to gauge where 3/4 throttle is, which is as far as I'm...
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    a word of thanks

    Greetings all, I just wanted to give a word of thanks to all that responded to my questions about rebuilding my 1990 40 hp Johnny. I used a manual but the info gleaned from this site was invaluable. This was my first rebuild and so I was a little apprehensive, but I took my time, used a camera...
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    new rebuild

    I have just completed my first rebuild on a 1990 40 hp Johnson(J40ELESR) thanks to some help from some of you guys. Anyway, I've got the engine mounted , the linkages reattached, and am in the process of disabling vro(will pre-mix from now on)and placing lower cowlings,etc. My question, the...
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    rod cap alignment

    Am finally in the process of rebuilding my 1990 40horse Johnson after waiting on rebore for what seemed an eternity. My Clymer manual says to use tool # so-n-so to align the rod end caps for this year model. Is there a way around this? The alignment looks and feels good on both sides and at the...
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    Gasket set

    My dealer finally got the gasket set for my 1990 40 hp Johnson. (now waiting on rebore and new pistons). Anyway, the set appeared to have at least twice the number of gaskets needed to rebuild the power head. Is this normal, do they put extras in for different models? It even had three diff...
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    40 hp rebuild

    My 40 hp Johnson, J40ELESR, burnt up the pistons. I have taken the powerhead down and sent the cylinder block for reboring. I am now in the process of ordering gasket kit, carb kits etc for the rebuild, will wait to see how much oversize needed before ordering new pistons. Even though this motor...
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    Taper Pin

    Can anyone tell me the purpose of a taper pin? I have a 1990 40hp Johnson that has just one which goes in hole between crankcase and cyl block. Is this a critical item? I am rebuilding this engine and may have to do so without the pin because of a major screw-up on my part during disassembly.
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    1990 40hp johnson

    Am trying to remove powerhead. I have everything off of engine but can't break it free of exhaust housing. My Clymer manual says to remove 4 bolts from underneath (?) exhaust housing and 2 retainer nuts(one bow and one stearn) however, I can only locate the one rear retaining nut. Book says to...
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    Engine housing

    I have a 1990 40hp Johnson that I need to do a rebuild on. I have taken all external components (carbs, contols,etc) off of engine, however I cant get to 1 out of 4 bolts that engine mounts to exhaust housing. It looks like the engine shroud itself is 2 parts that should come off giving me...
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    motor rebuild

    I have a 1990 40horse Johnson that died on me. Two different marina's says the motor will need rebuilding. Has 50# compression on 1cyl and 110# on #2. The second mech. pulled the head to show me the scoring on the cyl walls. I suspect that the VRO failed as oil consumption has been very little...
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