1986 Johnson 9.9 Frankenmotor

[pckeen]

I picked up this motor, non-running for parts, with several other old motors. The powerhead and housing looks like a 1986 9.9 Johnson. The lower unit isn't original to the motor. The transom mounting bracket is from a 1971 60hp Johnson. It had apparently been sitting in someone's shed for years. When I opened it up, it looks like someone put on....new fuel lines, a new powerpack and ignition coils. It has good spark. Compression is OK (94 and 100 when dry, 112 and 120 when fogged). When I removed the lower unit drain plug, out comes clean, fresh lower unit oil. Hmmmm....that left the carburetor.

Removed the carb, and it looks like it has a new float and new needle....BUT, the float bowl was dirty and it has old cracked and ripped gaskets, and someone coated the gaskets joining the carb to the manifold, and float bowl to the body, with some sort of liquid sealant which softens when in contact with carb cleaner. That explains the 'non-running.' Weird. I spent an hour or so cleaning off the silicone, which had pooled inside the float bowl. A carb rebuild kit is on order. The other thing I noticed is that where the screw for the jet would be on an older carb is a core plug. Not sure if this is normal or not.

Last thing - the motor moves in and out of gear easily, but sometimes it's tough moving it into reverse. I've spun the prop, and sometimes this makes a difference, sometimes not.

Three questions
1) What is the proper initial adjustment for the lean/idle mix?
2) Is the inside of this carb normal or not (see the pic below)?
3) Are there any tricks to moving this in or out of gear?

 

[racerone]

Throttle should be at idle for shifting.-------Motor must be running or prop must be turning while trying to shift.----Carburetor looks normal.

 

[jimmbo]

The transom mounting bracket is from a 1971 60hp Johnson. ]

What makes you say that? I can see what looks like clamp screws

 

[pckeen]

What makes you say that? I can see what looks like clamp screws

You see right. But the model number on the transom bracket plate is 60ESL71C.

 

[pckeen]

Any idea how the wiring should be run round the motor? The whole thing looks like a rats nest at the moment.

 

[jimmbo]

You see right. But the model number on the transom bracket plate is 60ESL71C.

Interesting... something is not Kosher there. Just for your info, a 1970 60 hp would not use a screw clamp bracket. Those engine were dropped into a transom brackets that were bolted separately to the boat

Initial setting for Idle mix screw, about 1 1/2 turns out from LIGHTLY seated. Racer covered the other two questions

The rats nest... From the pics, it looks pretty tidy

 

[pckeen]

Interesting... something is not Kosher there. Just for your info, a 1970 60 hp would not use a screw clamp bracket. Those engine were dropped into a transom brackets that were bolted separately to the boat

Thanks for the tips - very helpful. My impression is that several people worked on this motor. My guess is that it has changed hands a few times, as each mechanic couldn't get it running. Some of the work was done very well....other work....not so well. When inspecting the carb during cleaning tonight, I discovered that the cam roller assembly was broken, and someone had tried to glue it back together. Needless to say, that didn't work.

 

[jimmbo]

It is a FrankenSon engine.

 

[CatTwentyTwo]

I have an 84 9.9 and can take some pictures tomorrow if it would help.

 

[pckeen]

It would - the way the wires are set up are making it tight to get the cowling back down. Thanks!

 

[CatTwentyTwo]

No Title

If you need more or different views let me know.

 

[pckeen]

That's very helpful. The wire clips on mine on the cylinder head are largely missing. There is a pinkish tinge on the white cylinder head on mine which is very slightly different than the white on the crankcase itself. Looks like someone replaced the cylinder head but didn't replace the wire clips.

 

[Chinewalker]

The clamp brackets are not compatible between an old 60 and your 9.9. The tag is likely what was swapped over. The only reasons I can think that someone might do something like that are to hide that the motor is stolen, or needed to get a motor titled and had a title in hand for a motor that was junk, so they swapped things around to make the 9.9 "legal". Whatever the reason, it's more than just a swapping of parts and the tag went with them - someone actually took the time to remove a tag from one motor and tack it onto another.

 

[pckeen]

The clamp brackets are not compatible between an old 60 and your 9.9. The tag is likely what was swapped over. The only reasons I can think that someone might do something like that are to hide that the motor is stolen, or needed to get a motor titled and had a title in hand for a motor that was junk, so they swapped things around to make the 9.9 "legal". Whatever the reason, it's more than just a swapping of parts and the tag went with them - someone actually took the time to remove a tag from one motor and tack it onto another.

Title wouldn't make sense, as there is no title on motors in Ontario. If it's stolen, I don't want any part of that, so I've called the local police to report it.

 

[pckeen]

Well, the police have been and gone. The officers comment was there is no way of knowing when the tag was switched. He'll look into it and see what he can find out. I still have the motor, and the parts are on order, so I'll fix it up, and if it turns out to be stolen, then the original owner will get a working motor back instead of a broken one. C'est la vie.

 

[pckeen]

The carb kit is now here. I have replaced the welch plugs. One of the plugs was a nice tight fit, right off the bat, before tapping it in. The other was slightly smaller than the hole, so it simply fell out. When I tapped it in with a punch, it then stayed in place nicely - probably because the dome deformed slightly when being struck. Does this sound right?

 

[thumbnut]

There is a pinkish tinge on the white cylinder head on mine which is very slightly different than the white on the crankcase itself. Looks like someone replaced the cylinder head but didn't replace the wire clips.

I bet the off color on the head is from a past overheating issue. There was never an off white color on those motors.

 

[oldboat1]

The carb kit is now here. I have replaced the welch plugs. One of the plugs was a nice tight fit, right off the bat, before tapping it in. The other was slightly smaller than the hole, so it simply fell out. When I tapped it in with a punch, it then stayed in place nicely - probably because the dome deformed slightly when being struck. Does this sound right?

Yes -- expansion fittings. tap to seal (can add some nail polish similar if desired. I just leave them as is.)

 

[pckeen]

The last part - the cam roller link is in - and on. But the adjustment on the roller doesn't seem right. The roller doesn't connect with the cam plate early enough (I think), and when I turn up the throttle, the adjustment screw in the link hits the carb body. The video shows it all. How should I adjust this?

 

[oldboat1]

Hmmm. Should be a washer on the inside of the plastic cam follower (next to the carb body). Is that in place?