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1986 Johnson 25 hp J25RDC

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  • 1986 Johnson 25 hp J25RDC

    Hello all,

    New here and kind of new to outboard motors but not carbs or combustion engines. I own a 1986 25hp J25RDC engine and have had it for about a year. The engine is in great shape and appears to have been well kept and maintained over the years. The engine would start first pull almost every time and didn't require the use of the primer plunger seen here 1986 J25RDC Johnson Outboard MANUAL PRIMER SYSTEM Diagram and Parts About 4 trips out ago it became very hard to start and required me to pump fuel in manually via the primer (about 5 to 10 pumps) until it would idle fine on its own. It would run great all day and fire back up first pull. But if it sat over night or longer I would have the hard start issue. So I figured I had a little trash somewhere in the slow speed needle valve or a passage way and I would clean it out and be back to running like a top. Well that isn't the case at least I don't believe.

    My carb (1986 J25RDC Johnson Outboard CARBURETOR Diagram and Parts seen here minus the bowl on mine is different) and every passage way appears to be clear and as clean as the day it was made. I've check all fuel lines and they are clear. I've taken the fuel pump (1986 J25RDC Johnson Outboard FUEL PUMP Diagram and Parts mine looks like this but uses o rings instead of a gasket #2 I believe its a newer version the old owner put on) apart and it seems to be fine. I also got the engine running and watched it pump fuel after disconnecting the fuel line from the carb. So I believe it is working as it should. If I cover the carb throat almost 90% or maybe a bit less she runs like a top at idle. So either I have a air leak or I'm starving it of fuel. Float level is set to the proper height, parallel with the carb body.
    What are your thoughts on this?

    I've sprayed carb cleaner over all lines and area's I believe could be sucking air and didn't seem to change anything. I don't know what else to look for at this point. I'm not saying I haven't overlooked something so I am willing to start over and try anything again. Thanks for any and all help you guys give me. By the way the tag on the carb reads 396167 MX 16 AL that helps.
    Last edited by ZedHead; 11-09-2014, 04:34 PM.

  • #2
    Bump, please someone speak up.

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    • #3
      Geez the responses are overwhelming. Not much of a forum if no one is using it.

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      • #4
        Hey, Zedhead. I'm only one guy here; am I not entitled to a vacation?

        I still suspect the fuel pump. I'd go there first. Also, make sure your gas is fresh - and preferrably ethanol free gas. You are right to check for fuel line leaks - only I'd do it with WD-40 and not carb cleaner. Are you using an aftermarket fuel line from the tank to the motor? Aftermarket primer bulb? They are notorious for causing this type problem. Especially the gray ones. Even factory primer bulbs can occasionally cause this problem.
        Last edited by Rebel Sympathy; 11-20-2014, 04:10 PM.

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