1990 Johnson 225 (CXESS) no power under load

[intradev]

In Februrary I purchased the above and it's never run correctly. In an effort to resolve problems I've done the following:

-Tested compression and it's >100 PSI on all cylinders
-Changed dual power pack system to single (see below)
-Purchased one brand new and one used power pack
-Changed and rebuilt flywheel to specm (magnet kit)
-Changed stator to match single system
-Changed regulator/rectifier
-Changed timer base
-Ensured adequate fuel was reaching the fuel system
-Ensured that no kill switches are connected, and I am not in S.L.O.W.
-Purchased a spare 225 Evinude for parts


The motor now starts much faster than before but still runs bad. It seems to run fine under no load but has 50-75% power under load. It's never revved up to full RPM no matter what I've done. Also, I discovered that the timing is not correct, it appears to be +/-10 degrees too high (it should be at 5 BTDC and it's currently at 4 ATDC) , and I have the low speed timing adjustment all the way back with no more left. In comparing the timer base position to the other engine, it's similar.

I feel like I need to resolve the timing no matter what and retest. Is there something I'm missing regarding the cross-compatibility of these ignition systems?

 

[countvlad]

Re: 1990 Johnson 225 (CXESS) no power under load

In Februrary I purchased the above and it's never run correctly. In an effort to resolve problems I've done the following:

-Tested compression and it's >100 PSI on all cylinders
-Changed dual power pack system to single (see below)
-Purchased one brand new and one used power pack
-Changed and rebuilt flywheel to specm (magnet kit)
-Changed stator to match single system
-Changed regulator/rectifier
-Changed timer base
-Ensured adequate fuel was reaching the fuel system
-Ensured that no kill switches are connected, and I am not in S.L.O.W.
-Purchased a spare 225 Evinude for parts


The motor now starts much faster than before but still runs bad. It seems to run fine under no load but has 50-75% power under load. It's never revved up to full RPM no matter what I've done. Also, I discovered that the timing is not correct, it appears to be +/-10 degrees too high (it should be at 5 BTDC and it's currently at 4 ATDC) , and I have the low speed timing adjustment all the way back with no more left. In comparing the timer base position to the other engine, it's similar.

I feel like I need to resolve the timing no matter what and retest. Is there something I'm missing regarding the cross-compatibility of these ignition systems?

i dont know much about the 225 motor or the ignition but you def have to fix your timing problem..

have you tried this: http://forums.iboats.com/showthread.php?t=228183

+-10is A LOT... thats day and night diffrence....if im not mistaken at idle it should be around 4-8 ATDC .. mine 120 1989 J is 6 ATDC @ idle and 18 BTDC WOT....

they all seem to run fine with no load... sounds like your WOT timing is off.... follow the instructons on the link.... keep us updated

 

[intradev]

Re: 1990 Johnson 225 (CXESS) no power under load

Looking like I got a bad example of someone who thinks that any part is interchangeable with anything else. I've been trying to use a non-quickstart timerbase (583024) when 583533 or equivalent was needed. My telltale here was a black/white wire on the powerpack and a white wire on the timerbase. I was able to find a 583533 but one side of it fails the continuity test.

 

[intradev]

RE: 1990 Johnson 225 (CXESS) no power under load

Installing a new timer base 584586 seemed to correct my timing problems. The motor ran mostly great, for 10 minutes. It never had the power or RPMs that my port motor did, but it was better. I didn't set the WOT timing yet.

Now I notice I've lost spark. After 10 minutes of "bliss" the motor started to lose power and finally quit. When I got back to the dock, plugged in the timing light-nothing. I pulled the #1 plug out, nothing. Same for #2. I took the power pack off and moved/unplugged/plugged the stator and timer base wires. Voila! Spark! Motor started RIGHT UP. Brand new power pack 586662 (was in original BRP box). Ground wire from power pack connected securely. Connectors on Timer base are very clean. Timer base passes OHM tests. Rectifier/regulator is charging batteries. Are these ignition systems really that touchy?

 

[jonesg]

Re: 1990 Johnson 225 (CXESS) no power under load

I don't know if they're touchy but electricity likes clean connections, nice and shiny then apply a dab of dialectric grease to protect from moisture.

 

[intradev]

Re: 1990 Johnson 225 (CXESS) no power under load

I will try and apply some dielectric grease to these but I'd be shocked if there were a connection problem. The pins on both ends are super clean. What I really feel is wrong is either my rectifier or stator works well for a while and then dies, which in turn screws up the power pack/timer base combo. Is this normally what happens?

 

[jonesg]

Re: 1990 Johnson 225 (CXESS) no power under load

with electronics anything seems to happen.

are you sure you have the correct flywheel?
Switching from two to one PP's requires a different version wheel,
the magnet spacing is different.

other than that, get a peak reading meter off ebay ( $60) , shop manual with the numbers for one PP and start reading the numbers.

http://cgi.ebay.com/ebaymotors/Mari...Z230353556405QQptZMotorsQ5fAutomotiveQ5fTools

 

[clanton]

Re: 1990 Johnson 225 (CXESS) no power under load

1990 looper V6 only has one powerpacxk, if it had 2 someone changed it. If you are changing it back to the orignal system, you need to check the temp sensors and wires. The temp sensor port side controls the Quick Start. idle timing is set ATDC. Wide open timing is set only after engine is up to operating temps, and timer base has shifted from the start sensors to the run sensors. Don`t know about the flywheel, you will have to check the numbers.

 

[intradev]

Re: 1990 Johnson 225 (CXESS) no power under load

Thanks all. Very helpful. Went ahead and applied dielectric grease to all connectors. Flywheels from 86-87 systems with the dual power packs are different than the later ones. The magnet stripes which actuate the timer base are in a different position. There's a PDF from CDI which illlustrates this, andI made sure I have the correct flywheel. But I hadn't been adjusting the WOT timing with the motor warm. Motor is running, and sounds like it needs another timing adjustment-but I keep breaking flywheel keys. I read the spec that says 140 ft/lb torque but I'm having a rough time getting this without an impact gun.

 

[jonesg]

Re: 1990 Johnson 225 (CXESS) no power under load

Try an electric impact wrench if you lack air.

 

[clanton]

Re: 1990 Johnson 225 (CXESS) no power under load

You should use a torque wrench on the fly wheel nut, with BRP gasket sealer on the threads.

 

[intradev]

Re: 1990 Johnson 225 (CXESS) no power under load

Broke another FW key. Even tried different flywheel and stator. Not convinced flywheel was tightened down enough. Loosened after 15 minutes of runtime. I purchased a new nut just to be sure but some quick questions:

1. Is there the possibility that the crank or some other imbalance is to blame? It doesn't look bent etc...
2. Is a Woodruff key from the hardware store OK? My local Johnson dealer saw it and said it would be fine
3. Is it possible to use rope inside of cylinder #1 to lock the crank while tightening to 140 ft/lbs with a torque wrench? I don't see of any other good way to block this off so as to determine torque.

 

[intradev]

Re: 1990 Johnson 225 (CXESS) no power under load

Need the OEM Flywheel key-307480. Hardware stores' keys are not hardened, and I was advised to use a Flywheel Holding Tool.