1996 Johnson Ocean Runner: Smoke From Odds Places

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Author Topic:   1996 Johnson Ocean Runner: Smoke From Odds Places

bud jones posted 05-15-2009 08:48 PM ET (US)
Howdy. I just got done doing a de-carbon procedure as outlined in thread: http://continuouswave.com/ubb/Forum3/HTML/007656.html
My boat is a 1987 TEMPTATION 2000, the motor is a JOHNSON OCEAN RUNNER 200. It had its lower unit replaced less than 5 hours running time (and about 8 weeks ago), at a generally recognized as reputable dealership for Johnson/OMC/Evinrude/Bombardier products. The service department also replaced impeller and thermostats while they had the boat and motor.
In the process of doing the de-carbon I noticed two oddities that have me more than a little concerned.
Smoke eminates from the front seam of where the lower unit meets the motor, and water streams from the port side cover assembly just over the lower unit and aft of the steering post.
Here is a annotated photograph showing the locations if I have described them poorly.
http://mu.org/~alex/pics/smoke_on_the_water.jpg
Also of note, immediately after getting the boat back (and after a 1 hour on water test paid for at shop rates) the "confidence stream" or "telltale stream" was more of a mist - removing the threaded plug revealed metal shavings plugging the outlet hole. After clearing these twice, I saw no more shavings and the telltale has been normal.
I have the relevant Clymer manual for this outboard, but I'm not finding anything that addresses my concerns in there. I have a mechanical background but not much experience with outboards.
Anyone seen this before? My gut is the shop pooched the lower unit install. I'd like to hear from anybody who has seen these symptoms before or knows what is going on.
Also, is it normal for water to outflow thru the center of the propeller exhaust port when running on the hose?
many thanks,
bud
jimh posted 05-16-2009 01:50 PM ET (US)
On many OMC V6 motors, at the joint or seam between the gear case and the midsection, there is a gap. The two surfaces do not meet perfectly flat and square, and this is, apparently, intentional. There are small gaps into the interior of the leg. In the normal operating position, this gap is under water. When running on a hose adapter, the gap is not covered by water, and it is possible that exhaust gas could escape from the gap.

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Author	Topic: 1996 Johnson Ocean Runner: Smoke From Odds Places
bud jones	posted 05-15-2009 08:48 PM ET (US) Howdy. I just got done doing a de-carbon procedure as outlined in thread: http://continuouswave.com/ubb/Forum3/HTML/007656.html My boat is a 1987 TEMPTATION 2000, the motor is a JOHNSON OCEAN RUNNER 200. It had its lower unit replaced less than 5 hours running time (and about 8 weeks ago), at a generally recognized as reputable dealership for Johnson/OMC/Evinrude/Bombardier products. The service department also replaced impeller and thermostats while they had the boat and motor. In the process of doing the de-carbon I noticed two oddities that have me more than a little concerned. Smoke eminates from the front seam of where the lower unit meets the motor, and water streams from the port side cover assembly just over the lower unit and aft of the steering post. Here is a annotated photograph showing the locations if I have described them poorly. http://mu.org/~alex/pics/smoke_on_the_water.jpg Also of note, immediately after getting the boat back (and after a 1 hour on water test paid for at shop rates) the "confidence stream" or "telltale stream" was more of a mist - removing the threaded plug revealed metal shavings plugging the outlet hole. After clearing these twice, I saw no more shavings and the telltale has been normal. I have the relevant Clymer manual for this outboard, but I'm not finding anything that addresses my concerns in there. I have a mechanical background but not much experience with outboards. Anyone seen this before? My gut is the shop pooched the lower unit install. I'd like to hear from anybody who has seen these symptoms before or knows what is going on. Also, is it normal for water to outflow thru the center of the propeller exhaust port when running on the hose? many thanks, bud
jimh	posted 05-16-2009 01:50 PM ET (US) On many OMC V6 motors, at the joint or seam between the gear case and the midsection, there is a gap. The two surfaces do not meet perfectly flat and square, and this is, apparently, intentional. There are small gaps into the interior of the leg. In the normal operating position, this gap is under water. When running on a hose adapter, the gap is not covered by water, and it is possible that exhaust gas could escape from the gap.