Johnson 140 4 stroke problem advice ??????

[went522]

Here's the story, I am running this motor on a Stratos 386. When I put the hammer down and just about to top speed"not over reving" the motor shuts down, doesn't do it all the time, maybe a half dozen times. I check my fuel ball and its soft. Pump it up and its good to go! My fuel vent "surge plug" is part of my gas cap, the cap has a plastic band much like a car. Is it possible that this band is holding my surge plug shut and not allowing air into my tank? This is the conclusion I've come to. The last few times I've been out I have made sure the band is not obstructing the surge plug, and have run perfect. Did I take care of my problem or am I dealing with something more serious. Any advice is much appreciated!!

BIRDDOG

[Josh G]

I have a 90 4 stroke Suzuki. Whenever I trailer a long distance, 3 hours or more, my motor will "chug" when I get to 3000 RPMs. The bulb will be soft. I pump up the ball and I am good to go until my next long trip. Any time I take a long trip I now make sure to pump up the bulb as soon as I put in. Is your case the same, or does it do it more than once a trip?

Josh G

[work2fish]

I have a problem similar to this on my Suzuki 140 (2002). I found my fuel line was not tightly connected to the motor, but even after correcting this I still have the problem occasionally and it is almost always at or near WOT. I had never had it happen until this year. It just sounds fuel related the way the engine dies... I wonder if any others are having this problems?

[went522]

Josh,
I always pump the ball before I put the boat in and it has done it more than once per trip.
Mike/co,
When your motor dies does it chug as if you are running out of gas or just cut out? Mine just cuts out!

[seahorse]

You can temporarily hook up an automotive fuel pump pressure gauge used for fuel-injected cars, and monitor the pressure as you run the boat. If it is continually low, you may have an electric pump problem or a restricted high pressure filter.

If the pressure is ok up to near the top rpm, you may have a boat or lift pump delivery problem. You need a piece of clear fuel line, a Tee fitting, and a vacuum gauge to test the boat's fuel system for any restrictions.

Your best bet is to get a service manual and understand the procedures, working carefully around pressurized gasoline, or find a QUALIFIED tech to troubleshoot it for you.

[MTJ]

I had the same problem with my 140 Suzuki (2004) last weekend. I have about 20 hours on it and it hasn't skipped a beat. Last weekend, after putting about 150 miles on it, I was headed to the landing to pull it out of the water. I was running WOT and the motor just died. No chugs, sputters, surges just died. Cranked over a little and started right up. Thought it was just a fluke. Now that someone has the same problem I will definitely take it in.

[Shorelunch]

My '03 Suz 140 has dropped RPM at WOT and cut off once - both in the same day in late May. I figured it was due to one month old gas. I think I posted regarding the problem and everyone thought it was due to old gas too -not to say that wasn't the problem though. Hasn't happend since. I always pump the bulb before starting.

[P.V.]

Ok, I have sold, rigg'd and changed initial oil/filters on quite a few of these motors. The only thing I can say is the following!! When the motor is first rigg'd up, the starboard side lower pan cover must be removed to connect the throttle and shift cables. When changing the oil filter at 10 hours, the cover, again, needs to be removed to access the filter. If you were to look closely when re-installing the cover, it is very EZ to pinch two fuel lines that run just below the filter. Depending on how much they are pinched, the motor may/will fall flat on it's arse due to lack of fuel!! So, you almost have to remove the cover on the strbd side to check and verify if these lines are a culprit!!! BTW, With the exception of the above concerns, I have NEVER had one lick of problems with these engines!!! Now, for the kicker, BOMBARDIER, has raised the cost $1000 for the '05 model 140 hp. It's my belief that BOMB is selling way too many 4-strokes (made in Japan) and not enough people are buying those e-tecs and Fichts (made in the USA).Perhaps that is because the four stroke 90, 115 and 140 and don't forget the 200 and 225, kick butt.... So let's make 'em less popular by raising the price !!! Thanks, Bomb!!! I may have to start sell Suzukis instead!!!!!! They always were cheaper, ya know!!!

[Great advice P.V.]

I pulled my cover off and sure enough two of the hoses were restricted, not totally pinched off but they were restricted!!!! I will run it and let you guys know if this helped. THANKS P.V.
BIRDDOG

[Shorelunch]

Was out this weekend and went about 10 minutes at about 5000 rpm w/ no problems. Left the first location after about 30 minutes and motor cut out at 5000 rpm (no chugging or any warning signs). The bulb was soft and didn't really get hard and my partner kept priming for a few minutes while I was driving. Stopped the motor and fished for another 1/2 hour. Checked the bulb and it was hard. Never cut out for the remainder of the weekend.

Anyone else figure out the mystery on theirs?

[Clipper]

Very interesting post! I have exactly the same problem with my 2003 Johnson 140. It typically will be running fine at 5000-6000rpm and will abruptly cut out. Usually no chugging or sputtering, it just stops and will fire up again right away although once it just cut rpm's and didn't die completely.

It feels like a fuel problem and I suspected water in the gas so put some gas conditioner in the tank and thought it cured the problem but not the case - it did it again.

Sure would like to know what the problem is because otherwise the motor is perfect.

[work2fish]

Happened to me again this weekend. I just turn the key again and it starts right up and messing with the fuel bulb is not necessary. I also experience no sputtering, it just seems to die like a person just shut it off so maybe it is not just fuel related?!? Strange...

I did check my fuel lines under the oil filter as recommended by P.V. above and it seemed to be normal and not restricted or pinched as far as I can tell...

[Birddog]

Hey guys, just got my boat back from my dealer, the tech said my sending unit on the tank was bad and he replaced it, he said it was sticking and restricting fuel, I havn't had a chance to run it yet so I can't confirm it's fixed. I will get it out a couple times this week and let you guys know!!

GOOD LUCK

BIRDDOG

[Birddog]

Birddog=went522

[haybaylarry]

It sounds like the restricion on the fuel lines are the problem but don't forget to check every fuel related fitting. One loose fitting can cause a surprising number of rough running and stalling problems....Larry

[Clipper]

So is it the consensus that this problem is caused by pinched fuel lines? I checked mine and they seem fine. Has anyone talked to their dealer about this?