johnson 35 -1999 problem

[kribulaator]

Hello! I?m from Finland and my english is not very good, but i am having a very strange problem with my johnson 35 hp -1999. At full throttle it just dies, like i was turning the key off...it starts immediately after in neutral and dies again when i try to give it more gas.. this problem comes and goes, some time it can work for days and then it?s suddenly back. I?m sure you have heard about this problem, because i have found zillions of post where people have explained exactly the same problem when i have googled it.
Is there someone that have experienced the same problem and knows what the problem is??

My model number is : BJ 35PL3EEM

 

[hidef]

Re: johnson 35 -1999 problem

First off has the oil tank and mixing chamber been removed? If it hasn't it is time to remove it as they are very prone to failure and run 50:1 pre-mix in your fuel tank.

I would check the emergency kill switch first to make sure the problem isn't with the ignition switch. Start by unplugging the plug with the black / yellow wire running into the power pack. If the issue goes away you have an intermittent short in the wiring harness or the controls. If it still persists you can follow the troubleshooting steps for the V4 / V6 with the optical ignition or preferable get the OMC / BRP service manual.

 

[kribulaator]

Re: johnson 35 -1999 problem

Okay I will check the wiring next time, but I want to remove the oil onjection anyway. Could someone describe the steps, and what i should do with the oil pump etc. I have tried to find a service manual for this motor but i can't get hold of one. None of my local dealers can find one, and i downloaded a manual a couple of days ago ( Johnson/Evinrude 1995-2001, 2-70hp) but when i got the manual it did not cover my 1999 35hp, it stopped at 1979.
Can someone please tell me where to find a manual for this motor, or send a link!

 

[hidef]

Re: johnson 35 -1999 problem

I have attached the link where you can order the manual and see below for disconnecting the OMS.

— 0787029 - Service Manual @ MarineEngine.com

The oil tank is very easy to bypass and do away with. Disconnect the wires going to the oil sender and remove the oil tank and oil mixing chamber. Once you have removed the oil tank connect the fuel filter (The fuel filter is between the fuel pumps and the mixing chamber) to the fuel line that connects to the fuel rail on the port side. Your are connecting 56, 5 and 11 together if you look at the attached schematic.

Until you get it disconnected you can run 50:1 in your fuel tank (which is what you will need to run after it is disconnected anyways).

http://www.marineengine.com/parts/j...EDC&manufacturer=Evinrude&section=Fuel+System

 

[kribulaator]

Re: johnson 35 -1999 problem

Okay thank you very much!
But what should i do with the oil level sensor? And are there more sensors that belongs to the oil injection system? Will not the gauge alarm if i leave the sensors disconnected?
I read about a S.L.O.W system that some johnsons and evinrudes have, how does that work?
Here is a link to a forum where a guy describes exactly the same problem that i have :

35 hp johnson 3 cylinder never ending problems - The Hull Truth - Boating and Fishing Forum

 

[hidef]

Re: johnson 35 -1999 problem

You unplug it and that is it. The circuit stays open and the alarm will not sound. The sensor is for low oil and no oil the the other sensor circuit is over temp.. The over heat alarm will still work. I look at at the link from the hull truth. Chances are your power pack is failing or it could be the optical sensor. The link recommends changing out both which isn't cheap.

 

[kribulaator]

Re: johnson 35 -1999 problem

Now i have unplugged and disconnected the oil tank and uses 50:1 premix, changed the powerpack and optical sensor, replaced all gas hoses to new ones, new filter (which is full of gas all the time)... and still the same problem... what else can it be???
It dies even when i have the kill switch cable unplugged!?

It dies 5 seconds after i hae revved up.. what should i do now, any suggestions what it might be?

 

[hidef]

Re: johnson 35 -1999 problem

Disconnect the two yellow wires running into the voltage regulator. It is located behind the air intake . Start the engine and see what happens.

 

[kribulaator]

Re: johnson 35 -1999 problem

I have also done that, still shuts off... there is a connector on those cables, i guess you mean that one?

Disconnect the two yellow wires running into the voltage regulator. It is located behind the air intake . Start the engine and see what happens.

 

[hidef]

Re: johnson 35 -1999 problem

Yes, it is you want to disconnect the two yellow wires at the connector. When you unhooked the kill circuit did you unplug it where it runs into the power pack?

 

[kribulaator]

Re: johnson 35 -1999 problem

Yepp! I unplugged the kill switch cable from the connector on the powerpack side... i have read that this problem is caused by piston failure, but i just can not belive that, because it behave just like the ignition cuts off... i have not tried to change the stator, but i do not think that is the problem either... what do you think i should do next? Is there anything i can measure with a voltage meter?

 

[hidef]

Re: johnson 35 -1999 problem

You verified that all three spark plugs are producing spark and you are using the Champion QL82C plugs? I would get a compression tester and check the compression just to be sure.

 

[kribulaator]

Re: johnson 35 -1999 problem

I have tested with both QL82C and QL86C, and i have taken a compression test and thatwas OK!

You verified that all three spark plugs are producing spark and you are using the Champion QL82C plugs? I would get a compression tester and check the compression just to be sure.

 

[kribulaator]

Re: johnson 35 -1999 problem

And yes all 3 cylinders have spark... it runs smooth until it "shuts off"

 

[hidef]

Re: johnson 35 -1999 problem

Check the CDI Guide starting on page 56 I know it is for the V4 but there are no instructions for the 35 triple. With all the testing that you have done I think it might be a bad stator but not sure.

 

[kribulaator]

Re: johnson 35 -1999 problem

aha okay thank you very much, i will check that!
But lets say that the stator is bad, would it really act like this then?

 

[hidef]

Re: johnson 35 -1999 problem

I don't know nothing else makes since unless the timing is off.

 

[kribulaator]

Re: johnson 35 -1999 problem

Now i have tried with another stator, and still the same problem.... out of ideas?

I don't know nothing else makes since unless the timing is off.

 

[hidef]

Re: johnson 35 -1999 problem

All grounds are clean and nothing is loose? With the rectifier disconnected from the stator and the plug with the sensors and kill wire disconnected from the power pack that should rule out everything else including the controls. That engine should run with no issues. You have checked the coils and plug wires? Unless the second power pack is bad.

 

[kribulaator]

Re: johnson 35 -1999 problem

Yep all grounds are ok! What " plug with the sensors " are you talking about? Butnyes it is very odd that it still will not work even if the kill wire an rectifier is disconnected...i have not tested the coils because i don't have a DVA adapter for my multimeter.. but is it possible that the old stator made the other powerpack go bad? Atleast i have read that a bad stator will make power packs go bad... the powerpack,optical sensor and stator is from a evinrude that had piston failure, so the seller said that they shoul be just fine.
I changed th powerpack and sensor last week, and tried with the stator today, so is it possible then that the stator made the other powerpack go bad instantly? Because i don't think it would break that fast...
Does the powerpack have some internal "kill function"?

All grounds are clean and nothing is loose? With the rectifier disconnected from the stator and the plug with the sensors and kill wire disconnected from the power pack that should rule out everything else including the controls. That engine should run with no issues. You have checked the coils and plug wires? Unless the second power pack is bad.