Johnson 4.5 carburetor woes

[coenvanwyk]

Gentlemen,

I bought a 1980 Johnson 4.5 hp long shaft outboard motor to use until I get my diesel inboard working. Model number J5BALCCC, serial no B003481.

It runs, but it idles and chokes/floods whenever I open the throttle There is a little too much friction in the throttle asssembly for the twist grip throttle to handle - the end of the throttle cable broke, and a new cable would cos as much as the motor did, so I made a new end out of brass.

I found an old 1977 4hp Johnson powerhead at a boat scavenger place, a basic motor with no forward/reverse, a throttle lever on the side, real basic stuff and what I should have bought but this one has no lower end and several parts are missing. I scored its carburetor, but it won't even go into the cowling due to the high speed mixture control, which my carb does not have. The float and needle and seat went into my motor, and the idle is better. I got it idling but still no high speed. Idle adjustment does not seem to make any difference, even screwing it all the way in and it still runs.

I have a carb kit on order, and in the meantime I made a new gasket to stop the fuel pump in the carb peeing fuel out. Still no high speed. I suspect the second needle and seat is still leaking.

Any ideas while I await the new carb kit? Some incantations? A reset button?

 

[VicS]

The model number you quote is not correct for 1980. It would be a 1988 model perhaps if such a beast existed but AFAIK the 4,5 was only produced from 1980 to 1983

The number for a 1980 model should read J5BALCSS, CS being the date letters for 1980. I am surprised your dealer did not query it when you ordered the carb kit. I hope you get the correct kit.

I don't understand what you mean by "made a new gasket to stop the fuel pump in the carb peeing fuel out".

You engine should be covered by the manual at http://162.144.28.33/lib/evinrude/manuals/1971-1989johnsonevinrude.html#/0 although there does not seem to be a diagram of your carb

This diagram taken from the BRP parts catalog, http://epc.brp.com/Index.aspx?lang=E&s1=71321d69-44e8-47df-9cfe-6b9fbc099f5c] , I believe shows your carb

 

[coenvanwyk]

Hi Vic,

Thank you very much for the image and the link. You are right about the model number, my fingers ran away with the C's. There are a few differences between the image and the actual carb, mostly dealing with the choke, and I think the previous owner made a few changes before making a makeshift choke. It works, somehow, but I would like to get it back to what it was originally.

The gasket that was in the carb is dry and cracked, with the result that, at the fuel pump, it let out a little stream of fuel. Since the other carb's gasket is different, I cut one from gasket paper. It seems to work for the moment. The fact that someone lost one of the screws and replaced it with a self-tapper does not help. I found a suitable screw but it slips when thghtened, I will probably have to drill and tap it to M5.

The kit which is on the way won't have the right gasket either, Amazon did not care what I ordered, and only later referred me to a kit which seems to have the right gasket. Neither of the suppliers to Amazon will ship to South Africa so i am having it shipped to someone in the USA who will return at the end of the month. We hope the kit will be there by then, at least I will have a new needle and seat and float. If not I will have to use a UK address of someone who will travel to Mauritius in August, and pick it up when we go there end August.

If you know a dealer that could advise as to part numbers etc it would be much apreciated.

 

[VicS]

Hi Vic,
.
.

If you know a dealer that could advise as to part numbers etc it would be much apreciated.

On the few occasions I have needed parts I have used Outboards Direct (aka Oakley Marine ) in Brighton http://www.outboards-direct.co.uk/
I've made an initial enquiry using their on-line "contact us" and had a prompt phone call back from someone who knows what he is talking about to check and confirm all the details and take my order.

Its very reassuring to have someone check the model details and the part numbers with you !

It takes a few days for stuff to arrive because they order from BRP and have to make up a minimum order themselves so it makes sense to order everything you are likely to need in one go I don't know if it still does but last time i ordered anything it had to be obtained from the BRP warehouse in Belgium

They claim to be able to ship outboards and parts worldwide!

 

[coenvanwyk]

Thank you for that, I will check with them. Out here the dealers/stealers tell you: Can't get parts, buy new.

I know this ancient Italian who has a scrap heap behind his store, and has mountains of handbooks. Always fun going out there, he is interested in tinkering, trying out ideas etc. But it is far and fuel is expensive.