Johnson 88 spl 1996 - Miss (Replaced Power Pack/plugs - no help)

68SSConvt

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My 1996 Johnson 88 spl has started a severe miss that prevents the engine from even idling at normal idle speed. It will idle at a fast idle. If I rev the engine the miss does not go away, so I have not tried to take the boat out. The miss is very consistent, every second or two, with a distinct puff through the exhaust. I identified the cylinder with the miss by pulling plug wires one by one until miss went away. I then swapped this plug wire and coil with another and the miss stayed with the same cylinder, so don't think the coil or wires are the issue. I then replaced the plugs and then the Power Pack. This did not solve the issue. What else would cause such a miss?

A little history - the boat is recently new to me. When purchased it ran fine, other than it seemed to require slightly more throttle than fast idle to start when cold (even using enrichment key press), and it is not very cold here in Florida, lol. Once it started it ran fine. I could run for as long as I wanted at less than 4500rpms and not overheat, but it would overheat if stayed near 5000 or more for more than a couple of minutes. So I didn't run it more than 4500rpms. I then replaced the water pump and this seems to have solved the overheating at higher rpms. After changing the pump I took the boat out for a test run and after warming it up I stayed at WOT, around 5200rpms, for a few minutes to test and it did not overheat. I went back in happy. The next day I took the boat out and could hear an occasional miss after I was out for a bit and it slowly got worse. The boat died as I shifted to reverse when pulling up to the dock and was hard to restart and had the consistent miss. Haven't taken it out since (a few days ago).

A little about me (my first post) - This is my first boat of my own. I have owned some older PWC's and have dove into various things on those and rebuilt one of those engines. (Yamaha 1200 npv.) I'm a car guy and general all around diy kind of guy and not afraid to work on anything. I'm new to boat engines, but figure they are still an engine.

I'm guessing the issue is now carb related, but not sure where to begin diagnosing this on this boat engine, and curious what would cause it to suddenly develop. The boat was driven on the lake at least every other or third day or more and have had no issues or hint of a miss until right after I replaced water pump. I don't see how replacing water pump would be related, but I think maybe the run at 5200rpms for extended test may be related to development of miss, but not sure exactly how since this shouldn't be an issue. But since I hadn't done that before due to overheating (and previous owner said he stayed around 4000rpm), I'm suspicious of that, but may just be purely coincidence that the miss started now.

Thanks in advance for any assistance,
Ray
 

interalian

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Your miss sounds like a 'lean sneeze' on the cylinder you pulled the plug on. Dirty idle passage possible.
 

oldboat1

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wouldn't hurt to check compression and see what you have. Might need head gaskets replaced (resurface heads if replacing gaskets).
 

racerone

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You start the trouble shooting with a compression test..-----Just took a 93 model apart yesterday.-------Found 3 cylinders in nice condition and one with a bad piston / broken ring.-------------A very common failure on these motors.
 

68SSConvt

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Just checked compression. Basically no compression on that cylinder. Crap that sucks. I checked all four when I purchased the boat this summer and all were good 125-135. Other three are still 125-135.

Dang, I don't really have time to do this myself right now, too many other projects and such and of course my real job. And the boat rides were a nice break between all this other stuff. Dang it.

What are the odds/chances it could just need head gasket and not rings or a piston? (I guess I will be diving in and checking that this weekend.) How hard is it to replace rings and possibly an upper piston on this outboard? Can I get at everything with the engine still on the boat or does the power head have to come off? Is the lower half of the cover going to be in the way, it appears to be one piece and doesn't look like I would be able to move it out of the way, if it is in the way at all. Are there any good web links on any of this?

Thanks for the help and quick replies!

Ray
 

racerone

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There are no short cuts.----Powerhead has to come off.------Lower cowling is not an issue.--Horseshoe cowling needs to come off to get at the powerhead bolts.------But maybe you just need a head gasket.-----Start with taking the cylinder head off.
 

emdsapmgr

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It is possible that the head gasket seal ring is defective on your low compression cylinder. Head gaskets do fail-usually associated with a massive overheat on the engine/head causing he gasket seal ring to deform and leak. Agree, Pull the head first and check before you pull the whole powerhead.
 
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68SSConvt

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I pulled the head and a ring did break, a few little pieces bounced around in there a bit. The cylinder actually looks okay at the top where I can see it, but of course I can't see the other half and of course looks aren't measurements. I have to figure out when I can fit this rebuild in my schedule or, reluctantly, pay someone to do it, or just sell it and buy something else (I hate the latter two options, but I have limited spare time right now). (Any guesses on what a V4 rebuild would cost in central Florida to pay someone to do it?)
 
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ezmobee

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Buddy of mine just paid $2400 last year for a rebuild on a V6 Merc with two damaged cylinders.
 

Faztbullet

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I would find a replacement motor as salty motors has a tendency to resist disassembly.......
 

68SSConvt

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exmobee - Thanks, that's about what I was estimated as a ballpark number by a local shop that I called this week, without them seeing it. I doubt I will go that route. I will just rebuild it myself when find time or sell boat/motor as is. This wasn't my dream boat/motor, it was just a good first boat and served that purpose well until this, so I think I'm just going to move on to next boat in my life. The only decision left on this boat/motor is whether I will try to sell as is or wait until I can rebuild the engine first and then sell.

Thanks everyone for your replies and assistance!
 

interalian

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Tough call, but you'd probably end up with more cash in pocket selling the lower unit, trim/tilt unit and a couple other parts then scrapping the rest vs. re-building and trying to sell it as a runner.

I went the rebuild route for sentimental reasons. As much as I'd like a different boat, it was a $1 deal from my parents. As long as they're around, this is my boat.
 

racerone

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The V-4 crossflow like yours is an elegantly simple motor.---New and used parts are everywhere and reasonably proced..---When rebuilt with a set of WISECO pistons it will run fine for another 20 years.---Other opinions will of course vary.
 
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