1992 40 HP Johnson flooding problem

[bigflathunter]

Engine model number J40TLENM. For the first trip out this year, I was having problems getting the motor to start and run well. Unburned gas/oil mix was bubbling up out of the water from the exhaust. So I took it home and rebuilt both carbs with carb kits. Now, I can get it to run (barely), but it is still running way too rich. The amount of smoke is unbelieveable. The smoke is mostly whitish in color (I think). The low speed adjustment screws are adjusted to 1.5 turns out from lightly seated.

I've noticed that the primer bulb will not get hard when pumping it up, and I've looked through the carbs and seen fuel squirting in when I pump the primer bulb when I have the flame suppressor off. I've also noticed that when I push the key in to activate the primer solenoid I do not get a click. The red knob is in line with the solenoid, as shown in the attached picture, so I'm pretty sure it is in auto mode.

I'm thinking the primer solenoid is stuck open, or the needle valve will not close properly due to me not adjusting the float correctly when I reassembled. But, would fuel shoot in through the primer jet when I pump the bulb if the needle wasn't seating?

I did try disconnecting the battery to see if the primer solenoid would close, thinking maybe there was a short in the ignition switch keeping it open. This didn't work either.

Any ideas? I've got the bug, and the warm weather is getting here so I really want to get this problem licked.

 

[HighTrim]

Re: 1992 40 HP Johnson flooding problem

How did you set your float? Was it parallel to the mating surface and slightly off when the carb is flipped upside down? Drop set to about an inch plus or minus 1/8"?

The primer solenoids normal operating position is to have that red lever positioned over top of the solenoid and aimed at the other end of the solenoid, gently turned to its stop. Pic compliments of TD



Follow the link below for applicable adjustments.

http://forums.iboats.com/showthread.php?t=167352

 

[bigflathunter]

Re: 1992 40 HP Johnson flooding problem

Based on your picture, the lever is in the correct position.

When I adjusted the float, it was parallel the carb body when held upside down, and about 1/8" (give or take) above the surface that mates to the bowl. I have considered taking them apart and adjusting it so that the float angles slightly up from the surface when the carb is held upside down, to ensure that the needle seats when the bowl fills up. Is this a bad idea that will keep the bowl from filling up enough?

I can provide pictures of pretty much anything on the motor that you might need to see. Thanks.

 

[tashasdaddy]

Re: 1992 40 HP Johnson flooding problem

did you change the needle & seat, and float, when you did the carbs. if you did not could be crud on the seat not allowing the needle to seat. also get a clean piece of fuel line, connect to carb, and blow thru it. make sure thing are sealing. carb upside down no air goes thru, right side up it goes thru.

 

[bigflathunter]

Re: 1992 40 HP Johnson flooding problem

New float, new needle, new seat, and new seat gasket.

The only problem with blowing through clean fuel line is finding fuel line in the right size around here. The only thing I could find is 1/8" line. The 5/32" isn't available anywhere in town, even to order. Believe it or not, that 1/8" really doesn't want to go over those fittings, it's so tight.

 

[tashasdaddy]

Re: 1992 40 HP Johnson flooding problem

auto part store has to have it. a piece of aquarium tubing. i believe you need 5/16 not 5/32.

 

[bigflathunter]

Re: 1992 40 HP Johnson flooding problem

Ok, I did the carbs again, and double checked the needle and seat are functioning. The primer bulb will not get hard when I pump it, and I can watch as gas squirts into the throat of the carb with each pump of the bulb. This happens with the primer solenoid lever in the run position (not in manual).

 

[tashasdaddy]

Re: 1992 40 HP Johnson flooding problem

there is only way it gets that far is thru the needle valve. see the sticky at the top of this forum.

 

[bigflathunter]

Re: 1992 40 HP Johnson flooding problem

Yesterday I watched the video on carb rebuilding. I've done the best I can do to duplicate those steps.

Last night and today I had a chance to do the carbs again. This time, I double checked that the floats were adjusted properly so the needle would seat when the bowl fills up. Then, after reassembling the carbs, I took a clean piece of fuel line and hooked it up to the main fuel inlet near the bottom of the carb body. I held the carb right side up, and could blow through it. Then I turned it upside down and tried to blow through, and couldn't, so the needle must be seating. I then reassembled and tried the primer bulb again, and got the same result.

Next thing I did was trace where the gas comes from. There are three lines that feed each carb, one down near the bottom of the carb body (main filler line for the bowl?), one line at the top that connects the two carbs together (what does this do, by the way?), and a small one on the top that appears to be the primer line. It goes directly through the carb body to a nozzle that angles towards the intake manifold. This is where the fuel is squirting in when I pump the bulb. I traced that line back to the primer solenoid.

I also looked to see where the VRO unit sends fuel. It sends one line to the top carb, one line to the bottom carb, and one line to the primer solenoid.

From the primer solenoid, two small lines go out, and each one feeds one of the small nozzles on the top of the carbs.

I tried pinching off the line that feeds the primer solenoid from the VRO with a pair of pliers, and pumped the bulb. Gas did not squirt into the primer nozzle on the top of the carb, instead it squirted into the main bowl line on each carb.

I just don't see how this primer line has anything to do with the needle valve. It doesn't seem to feed into anything but the top of the carb for it's own dedicated little nozzle.

Am I missing something? What does this all mean?

 

[tashasdaddy]

Re: 1992 40 HP Johnson flooding problem

you either have a bad primer or the red handle is in the wrong position. see picture in High Trims post. the picture the red knob is in the regular position. there should be nothing coming thru the primer lines. those line act like the old choke, they squirt fuel in when starting a cold motor. it is activated by turning the key to on and pushing the key in. your carborator, does not have the choke butterfly, it only has the throttle butterfly.

the line connecting all three carbs together feed fuel to all the carbs.

 

[bigflathunter]

Re: 1992 40 HP Johnson flooding problem

The local marine shop had a new solenoid in stock for my motor. I picked it up and put it on in about ten minutes, and pulled the boat out into the driveway and lowered the motor into the water trough, and it fired up and ran like a champ.

I even took it to the lake this evening, caught a few white bass and crappie.

I do notice, that now it will run great with the fast idle lever pulled up a little bit, but when I put it all the way down, it sputters and dies eventually, like it is trying to idle too slow. Should I just adjust the idle speed a little bit? It doesn't sound like it's running lean, but it's not smoking enough to seem like it's running rich, either.