Moderated Discussion Areas
  ContinuousWave: Whaler Performance
  Anyone with experience installing new johnson 90HP?

Post New Topic  Post Reply
search | FAQ | profile | register | author help

Author Topic:   Anyone with experience installing new johnson 90HP?
raygun posted 08-13-2002 08:19 PM ET (US)   Profile for raygun   Send Email to raygun  
After the dealers told me 10 hrs to install a new 2003 johnson 90 motor on my montauk, at 80+ bucks an hour, i'm gonna do it myself. A bonus is I will be able to neaten up the harnesses and hoses, etc. Has anyone used their older(86) binnacle mount control on this motor? I am at least going to get the new tach with the system check, but man the dealers out here aren't too cheap. 5270 is the cheapest i have seen the motor thus far, which sounds way high. Any advice on wheeling and dealing and installation is very appreciated.
Bigshot posted 08-14-2002 10:57 AM ET (US)     Profile for Bigshot  Send Email to Bigshot     
Not too high for an 03. Controls will work, just have to get another harness adapter for like $40. Installation is easy. Rent an engine hoist(cherrypicker) for about $25 a weekend and do the swap. A good weekend project if all goes smoothly. Most places charge about $3-500 for an install.
raygun posted 08-14-2002 04:08 PM ET (US)     Profile for raygun  Send Email to raygun     
thanks bigshot, i just needed some encouragement. after removing all but the 4 mounting bolts today in an hour and a half, and crawling around under the console i see it isn't that hard. I sure as heck am not going to pay some dealer the 800 he wants. If i can R&R cadillac motors.... got the steering out by loosening the motor as described here in the forum in old postings. thanks everyone. Think i should start with one hole up on the mounting?
Bigshot posted 08-14-2002 04:22 PM ET (US)     Profile for Bigshot  Send Email to Bigshot     
Do a fixed jackplate...worth the $150 and you can raise and lower in a few minutes to get the ultimate height. I have mine on a 6" setback and my plate is just above the drain hole so about 3.5" up I figure. Handles like it is on the transom but yet I get almost 4 inches more clearance and better speed and MPG.
raygun posted 08-14-2002 05:11 PM ET (US)     Profile for raygun  Send Email to raygun     
thanks, but can you give a product name or a link to one? I really want to know what to get before i ask a dealer for one and get a pile of you know what.
Wild Turkey posted 08-14-2002 05:49 PM ET (US)     Profile for Wild Turkey  Send Email to Wild Turkey     

Like Bigshot, I highly recommend the manual jackplate. Mine is a CMC ML-65. Here is a link to thier website:

Here is a pic of the setup on my Montauk:

Other manufacturers include Springfield, Rite-Hite & Bob's Machine Shop, but I have no experience with those setups.

Bigshot posted 08-14-2002 06:02 PM ET (US)     Profile for Bigshot  Send Email to Bigshot     
I have a Vnace. Got it on E-Bay for $139. I would however recommend a full plate, not a 2 piece. Mine is a 2 piece but I bought a 1/4" plate to make it a 1 piece......anyway look atthoe sites above and even check out E&B etc.
masbama posted 08-14-2002 08:41 PM ET (US)     Profile for masbama  Send Email to masbama     
Raygun: I have a 2002 90 Johnson. What are the differences in the 2002's and the 2003's?
raygun posted 08-14-2002 11:47 PM ET (US)     Profile for raygun  Send Email to raygun     
masbama- i haven't got it yet, but i am talking with the area factory distributor to find one for me in white, so i will ask him.
I don't think i am going to go for the jackplate. top speed isn't a real concern for me, and i want to keep costs down. so many dealers around here are just plain evil.
880 to 1000 dollars on the install from the dealers. unbelievable. and some of them trying to mark up the new tach with system check 30 bucks over standard parts pricing. this is after he tried to sell me the tach and a seperate system tach gauge. even had one guy try to sell me wiring harness adapters that don't exist, above and beyond the wiring harness adapter that is required. he wanted to charge me 170 bucks instead of 65 on the wiring adapters. waiting for one guy to call me back, i bet he tries to sell me new battery cables(which come with the motor from the factory). oh, and my 3 year old control cables are no good they say. jeez. it's just sick. i have dealt with ferrari and alfa dealers and they never tried any of this s#$%. 4 bolts, connect one steering cable, 2 control cables, fuel and oil lines and some wiring? 1000 bucks? the bombardier area distributor rep was appalled as well. anybody else ever get treated like this?
raygun posted 08-14-2002 11:51 PM ET (US)     Profile for raygun  Send Email to raygun     
seperate system check gauge i meant.
raygun posted 08-15-2002 12:04 AM ET (US)     Profile for raygun  Send Email to raygun     
tommorrow i am going to call the guy back who wanted 1000 bucks and ask him how much crack cocaine he had figured into that bid.;)
jimh posted 08-15-2002 01:25 AM ET (US)     Profile for jimh  Send Email to jimh     
Keep track of your time and see how many hours it actually takes you. I think you may be surprised.

I was amazed at how long it took me to just re-route and clean up the control cables, etc., at the back of the boat when I moved the engines onto 10-inch setback brackets. I had several hours invested in just re-running a few cables, cleaning up the ty-raps, etc, and getting the installation looking good. That was without installing anything new--just cleaning up the old installation.

I can imagine it would be quite a project to start from scratch--there is always a little hesitation to take a drill to an untouched transom and bore that first big hole.

bocaspiff posted 08-15-2002 09:38 AM ET (US)     Profile for bocaspiff  Send Email to bocaspiff     
It may take more time to do it yourself but knowing it's done right, the way you want, and the troubleshooting skills gained are all worth it, no?
raygun posted 08-15-2002 10:30 AM ET (US)     Profile for raygun  Send Email to raygun     
bocaspiff- Here here! My thoughts exactly.

jimh- this is a repower. no new cables. no new holes. switch from evinrude to johnson. And so far i have 1.5 hrs in to remove the old one. (all except hoisting it off, as i want to rent the picker only once.) they wanted 3 hrs just for that!!!!

bocaspiff posted 08-15-2002 10:35 AM ET (US)     Profile for bocaspiff  Send Email to bocaspiff     
Sounds like you shouldn't have any problems doing the work. I am the crew chief for an offshore racing team and you wouldn't believe the work we put into rigging our boat. 30' Cat twin Merc 2.5 EFI.
bocaspiff posted 08-15-2002 10:38 AM ET (US)     Profile for bocaspiff  Send Email to bocaspiff     
I repowered my old Newport a few years ago, 85 Javelin (Johnson) to a 115 Yamaha. No problem, used the cherry-picker. I just bought an 88 Montauk with a 100 GT. Any ideas on how to remove a broken screw? I don't want to damage the G-coat
raygun posted 08-15-2002 11:08 AM ET (US)     Profile for raygun  Send Email to raygun     
boca- a broken engine mounting bolt? how/where is it broken?
bocaspiff posted 08-15-2002 11:22 AM ET (US)     Profile for bocaspiff  Send Email to bocaspiff     
I broke the forwardmost bow rail stanchion base screwhead. The thing just popped off as I tried to unscrew it. I don't want to damage the g-coat but i have to get the thing out.
rb posted 08-15-2002 12:07 PM ET (US)     Profile for rb  Send Email to rb     
Curious why you recommend the full plate over a 2 piece system. My thinking was the 2 piece would snug up better on the rounded transom of my old 16'
george nagy posted 08-15-2002 12:26 PM ET (US)     Profile for george nagy  Send Email to george nagy     
I just finished rigging a 1997 omc 150 on my 18'. Because I re-wired the entire boat it did take me quite some time. The actual rigging of the motor didn't take that long.

I do recomend getting a new wiring harness instead of the adaptor plug. I would also get a new binnacle, especially if it is with an integrated keyswitch. there is an outfit in ft.pierce FL that has them for around $100-$250 some with key.

One thing I recommend is that you bundle all cables together and run them through the chase at once. I also recomend running a small rope with them so you can run other stuff later.

Mounting the motor takes the least time just hoist, calk, and bolt.

Adjusting the cable linkages is the most tricky, in fact I'm not shure I have mine set propoerly yet. You can always bring it to the dealer for an hour or two for some adjustment.

Good luck and take it slow you should have fun while doing it.

bocaspiff posted 08-15-2002 01:09 PM ET (US)     Profile for bocaspiff  Send Email to bocaspiff     
Mr. Nagy
Did you used to work for Bennett Marine?
Bigshot posted 08-15-2002 01:16 PM ET (US)     Profile for Bigshot  Send Email to Bigshot     
2 piece on a heavy engine can have side to side movement....I said CAN. I would rather have them as a solid mount, especially on a 320lb engine.

On a 16 if you mount to the curve, the engine(which is straight) still has to mount to the bracket(which is now curved), not sure how that would fair. Clark might have a better idea being he has mounted plenty.

Not saying a twin bracket is not strong but at least use some channel aluminum to connect the 2 sides via the mounting bolts. What I mean by that is mount the bracket sides, install the engine, then get the aluminum transom braces that go from the left top bolt to the right and install them on the inside of the plate as a reinforcement. Hard to describe without a pic. The brace I am talking about can be seen in the cetacea. Most mount inside the splashwell and it may have a whaler logo engraved on it etc.

george nagy posted 08-15-2002 01:16 PM ET (US)     Profile for george nagy  Send Email to george nagy     
No. why?
bocaspiff posted 08-15-2002 01:47 PM ET (US)     Profile for bocaspiff  Send Email to bocaspiff     
My Dad used to work for Bennett Marine 10 years ago and George Nagy used to work there. I grew up at Bennnet and I just remembered the name, that's all.
george nagy posted 08-15-2002 02:24 PM ET (US)     Profile for george nagy  Send Email to george nagy     
Well boca spiff you and bocadrew have similar setups. We should have a boca rendezvous some day soon.
bocaspiff posted 08-16-2002 09:01 AM ET (US)     Profile for bocaspiff  Send Email to bocaspiff     
Sounds good,
We are almost always out in Boca Lake on the weekends and wakeboarding south of 40th Street. I just got a 21" SS 4 Blade raker vengeance for my boat. Tested it last night with all the wood off. You don't want to know how fast.
masbama posted 08-16-2002 12:04 PM ET (US)     Profile for masbama  Send Email to masbama     
Raygun: When I repowered in March I kept my 1995 binnacle and cables that were used on a 1990 Johnson 60. I also had my dealer put on a wiring harness adapter instead of a new one. I did have trouble Memorial Day weekend. It was the wiring harness. I don't know if it was a fluke or if the adapter isn't the best way to go. I debated at the time of the repower and hindsight shows I should have gone new with the harness. The 2002 Johnson 90 runs great now.
Just some thoughts.....
raygun posted 08-16-2002 11:03 PM ET (US)     Profile for raygun  Send Email to raygun     
yeah, i'm going with the adapter. nobody in seattle wants to sell a motor??? so i got a guy near portland who's getting me one. only problem is white isn't avail. oh well. the graphite isn't that bad. and he's only charging me 240 bucks to install it. way better than 1000 bucks. I have the old motor off and everything(there isn't much) cleaned up and labeled so i forsee no problems. he's even doing it same day. plus i don't have to pay sales tax.:) that covers the gas and the install and almost the new system check tach.
he's charging me 4 hrs and i know it'll take 1.5 they way i have everything ready to go, but he's on the ball and he's gotta make some money. I should be back in the water in a week! yippie!
masbama posted 08-18-2002 10:43 PM ET (US)     Profile for masbama  Send Email to masbama     
Raygun: Are you going with the VRO or not? If not, you won't need the system check because it mainly moniters oil flow. Just a thought....
raygun posted 08-19-2002 03:07 AM ET (US)     Profile for raygun  Send Email to raygun     
yep, going with the oil injection. never had a problem with that on the 86 rude. plus my tach has a broken trim ring and needs replacing anyways which is why i'm going for the new tach with the system check instead of the seperate system check gauge.
TightPenny posted 08-23-2002 08:54 PM ET (US)     Profile for TightPenny  Send Email to TightPenny     
Having installed a 60hp Johnson that I owned on my Montauk, and then repowering to a 90hp Johnson, I gotta say that it is a weekend project if you take your time doing it.

It is not difficult, but some of the aspects can be a little tedious. But it is much more satisfying to do it yourself.

Post New Topic  Post Reply
Hop to:

Contact Us | RETURN to ContinuousWave Top Page

Powered by: Ultimate Bulletin Board, Freeware Version 2000
Purchase our Licensed Version- which adds many more features!
© Infopop Corporation (formerly Madrona Park, Inc.), 1998 - 2000.