2003 Johnson J90PLSTC Starting issues

ejis4lsu

Cadet
Joined
Jul 7, 2014
Messages
10
I have a new to me 2003 Johnson 90hp 2 stroke, problem that I am experiencing is bendix 'kicks' out before engine fully starts. When the bendix falls back down after 1-3 turns of the flywheel, I can still hear the starter turning. I have taken the bendix shaft apart, cleaned and inspected. It looks and operated as it should; teeth on bendix and flywheel are as they should be. I have a hot battery and good voltage.

I am able to 'pop' the key switch which appears to kick the bendix into the flywheel, then turn the key again and it will start up. When started, the engine runs like a charm. I have not checked compression but wouldn't think anything is low as the motor runs well.

What's next?!

Thanks all in advance!
 

James R

Commander
Joined
Feb 1, 2007
Messages
2,678
These motors and all of the similar design seem to be very sensitive to battery condition and cleanliness of connections. Might try there.
 

Chris1956

Supreme Mariner
Joined
Mar 25, 2004
Messages
27,942
When the engine fires, the bendix is supposed to disengage. The bendix is doing what it is supposed to do. The issue is why the engine is not starting when that happens.

Usually it is a issue where the motor is out of tune. Make sure the primer bulb is hard, and hold the choke closed and crank her until she starts. if that doesn't work , you have other issues.
 

ejis4lsu

Cadet
Joined
Jul 7, 2014
Messages
10
When the engine fires, the bendix is supposed to disengage. The bendix is doing what it is supposed to do. The issue is why the engine is not starting when that happens.

Usually it is an issue where the motor is out of tune. Make sure the primer bulb is hard, and hold the choke closed and crank her until she starts. if that doesn't work , you have other issues.
You were correct, it wasn’t anything to do with the starter system. Pulled the plugs to see how the engine turns over, along with a compression check. Found a hole in one of the pistons. Dangit!
 

Chris1956

Supreme Mariner
Joined
Mar 25, 2004
Messages
27,942
Gee, "Dangit" doesn't cover that issue, IMO. "Rats" is necessary.

A hole in the piston is bad. I would think the block needs to be inspected to see if there is any other damage.
 
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