2003 Johnson 4-stroke Long Beep Alarm

[lipinski]

I recently purchased a used pontoon that has a 2003 (manufactured in '02) Johnson 4-stroke 50HP motor.

Whenever I start the motor, I get a long (and very loud) beep from the console - maybe 30sec. The beep stops and the Check Engine light remains on. The motor seems to run fine. We have had the boat out a handful of times with no real issues. There seems to be some hesitation at full throttle, but I was told that could be due to a slightly bent prop blade - which there is.

I did notice that if I turn the key to On, but don't start the Motor, the Check Engine light seems to flash in a pattern of either 23 or 32.

Any ideas of what I should look for?

FYI - I have two other problems that seem unrelated, but maybe not - my Fuel Gauge doesn't work (I know there is gas), and the RPM Gauge doesn't work (it's pegged at like 1800 RPM).

 

[JB]

Re: 2003 Johnson 4-stroke Long Beep Alarm

Howdy ski.

Welcome to iboats.

Your engine is a rebadged Suzuki DF50. You need a Service Manual to 1. Decode beep codes and 2. Get your fuel guage and tachometer working.

My guess is that the ECU is demanding service.

 

[lipinski]

Re: 2003 Johnson 4-stroke Long Beep Alarm

Howdy ski.

Welcome to iboats.

Your engine is a rebadged Suzuki DF50. You need a Service Manual to 1. Decode beep codes and 2. Get your fuel guage and tachometer working.

My guess is that the ECU is demanding service.

JB - Thanks. Luckily our local library carries the Seloc manual - so I can get it soon without waiting for shipping. I'll pick it up tomorrow to determine the diag code and gauge problem

 

[fishboy31]

Re: 2003 Johnson 4-stroke Long Beep Alarm

it could be as simple as a # of hours indicator...my Suzuki does it as a service reminder

 

[JB]

Re: 2003 Johnson 4-stroke Long Beep Alarm

SELOC is not going to help a bit. It does not have the code chart for the ECU interface beeps.

 

[lipinski]

Re: 2003 Johnson 4-stroke Long Beep Alarm

ok - made some progress, but still need quite a bit of help.

Again - Johnson 4-stroke 50HP - J50PL4ST model

Code is 2-3. (Hard to tell because it blinks 3 first, but the order is as such:

3 - long_pause - 2 - short_pause - 3 - long_pause - 2 - short_pause - ...

So, per the book, and according to the local Johnson dealer, that is code 23.

Code 23 is the IAT (Intake Air Temp Sensor). I checked the resistance across the Sensor itself, and that seemed within normal range.

I asked the dealer about ordering a new IAT, and they were hesitant. They claimed that they have never replaced one before. So. they don't think that is the problem. They are very helpful, but not very close to where my boat is, so a service call would be expensive.

What should I do next?

The SELOC mentions replacing the IAT (if resistance out of range - which, best I can tell, it is not). Then, mentions a wiring break or ECM failure. I can't tell where the wiring from the IAT travels, but I'm planning on tracing that down next.

Any ideas would be most helpful...

P.S. - I did have a split intake air silencer, so I replaced that. I seemed to think it was odd the inside of the silencer was coated in oil/grease/grime...

 

[lipinski]

[SOLVED] 2003 Johnson 4-stroke Long Beep Alarm

[SOLVED] 2003 Johnson 4-stroke Long Beep Alarm

Ok, solved the problem with the long alarm and Check Engine code 2-3.

It took some time with the multimeter, but I found that continuity failed between both contacts of the IAT connector and the ECM Harness. For those interested, on this motor it's contacts 11 & 31.

I found it very odd that both wires were bad, but after some tracking and cutting a few "probe points" in the wires to find the break, I found it - both wires were broken within their insulation about 1" down from the IAT connector.

I could not find replacement contacts for the IAT connector, so I had to solder and heatshrink both wires. After that, all was well.

Thanks for everyone's help...

 

[AlTn]

Re: 2003 Johnson 4-stroke Long Beep Alarm

your info and troubleshooting might be welcomed at the suzuki forum as well, if you have time to post it there

 

[clanton]

Re: 2003 Johnson 4-stroke Long Beep Alarm

The oil in the air silencer comes from the crankcase breather. The hose comes from the valve cover. There is a baffe inside the cover, sometimes the baffee drain hole is filled with gasket sealer. Remove cover clean drain.

 

[Silvertip]

Re: 2003 Johnson 4-stroke Long Beep Alarm

The crankcase ventilation system routes crankcase vapors to the intake so they can be dumped into the combustion chamber and burned. Hence the oil film.