1982 Johnson 15 HP repair

Newtosa · Post by **Newtosa** » 27 Oct 2019, 11:00

And the checklist I made, based on that reference is below. I just keep it in Google keep, so I can use it as a checklist when I'm working on an engine. You'll find some of this can get into a religious debate, so I should preface this by saying there are several acceptable answers here.

[x] Carb to manifold: oil
[x] Intake manifold to reed plate: nothing*
[x] Reed plate to block: nothing* (check old gasket and new)
[x] Exhaust cover to plate: Permatex 3
[x] Exhaust plate to block: Permatex 3
[x] Bypass covers to block: Permatex 3
[x] Head to block: labeled do not use anything
[x] Power head to exhaust housing: Permatex 3
[x] Inner exhaust tube gasket to exhaust housing: black or ultra black
[x] Crank case halves: 847 on spaghetti seal and the stationary upper and lower o-rings
[x] Gear case halves: 847 on spaghetti seal and the stationary upper and lower o-rings
[x] Lower unit to exhaust housing: 847 or 518/51813
[x] Impeller gasket (if present) : Permatex 3
[x] Impeller housing to plate (if no gasket): 847
[x] Impeller plate to lower housing: 847
[x] Seal outer diameters: 847
[x] Bolt threads: Permatex 3
[x] Bolt threads for exhaust cover: aluminum anti seize, or just grease
[x] O-rings: red grease (all o-rings except inside crank case halves and gear case halves)

CMOS · Post by **CMOS** » 04 Nov 2019, 13:10

Update: Got the Power Head back on the main cowling yesterday, and started the process of getting things buttoned up.

Just need to follow the pics I took as I took it apart to keep the right grounds, etc.

@Pappy

CMOS

Post by **Pappy** » 05 Nov 2019, 00:19

Looks like a good clean job so far!

CMOS · Post by **CMOS** » 03 Oct 2021, 16:41

@pappy

Well guys it's been long time since I touched this motor but now that it's getting a bit cooler and the COVID insanity is simmering down I'm back on the job .

I'm putting everything back together but noticed a problem when I put the carb back on: When I advance the throttle, the CAM throttle roller is hardly being moved by the Throttle Control Cam. The whole magneto assembly just isn't rotating enough to even come close to 1/2 WOT.

Thoughts?

Pic below of the most travel I can get:
CMOS

Post by **Pappy** » 03 Oct 2021, 18:01

Put it in gear

CMOS · Post by **CMOS** » 03 Oct 2021, 18:33

That's right! The throttle travel is limited in Neutral!

Thanks Pappy. I should be able to finish her up tomorrow.

CMOS

CMOS · Post by **CMOS** » 20 Nov 2021, 15:04

@pappy

Just about done, but cannot get the lower unit to mate with the main housing. See attached pic. I have the shifter lever in the Neutral position, but I just can't get the lower to insert any higher.

Thoughts?
CMOS

20211120_125854.jpg

CMOS · Post by **CMOS** » 20 Nov 2021, 16:04

Disregard. Got it!

CMOS