+AdamJohn79, From what the boating forum folks told me & some other heavy hitters in the outboard community this may have only been a issue from 79 thru 82 35hp motors. kodi
@@kodibassInsideoutboards QL77JC4 - Champion Spark Plug Are they ones i have got them from a marine repair shop. Just unfortunately dont have the funds right now to have them even diagnose it thanks 🙏 🙂 ♥
They started to mill it at the factory and the mill stopped for some reason. The guy running mill pulled that manifold out and it accidentally got put into the “ready to fit” pile at the factory.
Hey kodi question,I have a 1978 25hp evinrude,if I take the carb off a 1975 35hp Johnson and put it on the 1978 25hp will I see a difference in speed ?
I love outboard motors so much! I started working on them, jumping from HVAC WORK to boat motors in 1988, and never looked back! I opened my shop in 1990 on the main drag in Medford, Long Island and I too had at least two motors that had the restricted hole in the intake manifold! I used to know 3 older guys who worked for Johnson and Mercury outboards,, but sadly they're all passed on now. I'm sure they could have answered the question that would solve this mystery! My first thought was that maybe all manifolds came cast that way, and either had the small hole ~stamped~ out,, and maybe at the factory, the workers might then enlarge the hole to match the h.p. of that particular motor! Who knows?!?!?! LOL!!! Really enjoy ypur videos Kodi!!!!! Sonny.
I know everybody has to put their 2 cents worth in on what they think happened here. heres mine.. I tihnk it was put on by mistake at the factory assembly line. i think it was accidental.
Reguardless of the hole size of the intake manifold, the fact that the bore center is not inline with the bolts tells ya that something is definately wrong. even if the intake was from a 10 - 15HP the bore center should be on center line of the bolt centers. this is a major screw up somewhere.
It looks to me that the casting was missloaded onto the machining process that makes the throttle bore. I have been on the machining end of Die-Cast for several years and that is the only thing I can think of.??
I bought a 1982 monarch 15' John boat 1542F actually and had had the same intake on the motor Thanks to this video I changed it out and bought a correct one for $25
@kodibassInsideoutboards ive got a 1977 Johnson 35 and a 1981 Evinrude 35. The Johnson is electric start and i like that but the Evinrude goes 12mile faster on the same boat
@kodibassInsideoutboards what prop would you recommend? Out of curiosity. I say im not after speed, just reliability and efficiency but there are times i do enjoy speeding
I think you may have a factory block that was put together for a market area that requires detuned engines, but during assembly to the mid-section and lower some how it got mixed up at the factory and ended up slipping out the door with US serial and model numbers. This is kinda like two headed coins that slip thru the Mints without detection.
@@kodibassInsideoutboards That’s amazing! I got lucky and scored the same motor (1983) for just $50. Been sitting for years. Sprayed 2 cycle oil in cylinders, turn by hand, cleaned carb, changed fuel lines, changed fuel pump as first one was deteriorated. Cleaned started brush, changed plugs to jc4. First gas tank mixed 50:1 plus a little extra splash, and now she starts so easy and idles fine. The only thing is at 1 1/2 turn out on carb it starts easy but sneezes and dies after a few minutes. But at 2 whole turns out it starts easy and stays running. So I left it there haha. Any tips? Bear in mind this is a new hobby so I’m a rook. Lol
So that's crazy I've rebuilt so many rude and Johnson's and never seen that I just bought a 35 rude from 79 good compression good spark starts cold on first try no prob but idk if a Reed's fucked up or carbs clogged but it's goes a little less than half full throttle I'm going to pull it and clean the carb I'm going to see if it has this I'll post when I pull the carb
That’s the first step to machining out the intake hole of the aluminum cast someone didn’t finish. Got distracted put it on and it went to paint etc. Get it machined the rest the way and it will work just fine.
That's exactly what I think. Years ago when I was a millwright, it was common for a component to fall from a roller bed or a bin. Workers under pressure for high quota often moved too fast to recognize it as out of place. They'd pick it up and put it back on the line, no telling how many stations it bypassed. It's the sort of thing QC wouldn't easily catch, because true manufacturing flaws tend to result in a bulk.
@@timothyclingerman5430 Ha! I never miss spending days or weekends trying to find imaginary problems in machinery, all because of one defect caused by simple human error. At least once, I needlessly replaced a bearing just so that managers would get off my case and let me have my time back.
I found the same problem in my 82, 35hp Evinrude, a pain in the ass to start. Just ordered a new manifold plate hope it works....also rebuilding the carb. The motor starts but it floods constantly. I thought it was the fuel pump but the problem persisted. Lucky for me I saw your video prior to taking the carb apart thanks so much I will keep you updated
I think what you might have there is a 388584 manifold from a '77 25 horse. It may have been put on to detune the motor if it was used in a lodge. These big inch 25-35 horse motors are the same internally from '77 on and they shared the same 396788 manifold from '78 on. The '77 manifold looks like a one year only item so it might be rare and worth a fortune to someone! Also, where is the motor made, Canada or USA?
Did you find anything out about the manifold. I have a J35elcnd and I have the same issue. Everything was like your all the paint on the bolts and edges of gaskets like it’s never been apart. Mine is part number 390655 but I can’t find which model motor it would have been installed on.
+john zudans, I could have cut the hole to match the carb but I wanted to save this one & do a bit more research on it, Also I have many other correct 35 intakes in the bone pile. kodi
Ive seeen them before with the offset small hole on 20HP models.What the OMC engineers did on very limited production numbers was cut corners & put a 35HP carburetor on a 25-35 block to drastically depower it to make it a 20HP.Thats why the highspeed jets are the same number value as the 35HP. It was a cheap way to make a 20HP model probably last minute decision.The ones I have seen had the same offset small hole like yours does not many but I have seen a few and used the large 35HP gasket. Hole doesnt have to be on center fuel aircharge doesnt know the difference as long as it gets in.I know its very strange but thats how they came I thought the same thing years back.Im my humble opinion that motor still has issues running in the tank shaking like a leaf,LOLL but your getting there love your videos......................... Glenn P. .
+GFPALL62, Very interesting info, O'Yes this motor has shot motor mounts & many other issues that need tending to, But owner just wanted me to get it running well & so it will start. I'll point out to him all the other issues 4 sure. His call & bank. kodi
@@kodibassInsideoutboards Oh the mounts are bad thats a good reason for the shakes,LOL.Back in the late 1990S I rebuilt a Saildrive Zephyr 15HP a converted detuned 25-35 a strange configuration to see by the way for a gentlemans sailboat. It might of had that manifold on it too like others have mentioned but not 100% sure it was a long time ago.But anyway looking forward to the next video keep up the good work ...GlennP.
@@kodibassInsideoutboards Actually, you would need at least a decent bridgeport (milling machine) and the proper tooling to be able to correct the off-centered hole, then pollish/burnish the hole to spec so that Whatever is recieving into the hole is a near perfect fit. It really woulden't be worth the trouble. I am sure Tony up there would agree.
I got an 82 off Craigslist that was practically mint except the head of a rod bolt popped off. I saw the same thing when I disassembled it and replaced it with a full hole 35. I saved everything to research just like you and also checked the jets. I originally thought someone put a 20hp power head on it. Now I’m seeing this was a 1982 thing… perhaps some strange epa crap.
Kodi, I learn so much from your videos! I picked up an 82 35hp (E35ELCND) for $100 this past summer. I watched your video before tearing into my motor and was shocked to see that mine has the same small opening at the intake. It is offset from center, and smaller than the carb opening and smaller than the gasket. The bolt heads holding the intake are factory fresh so I can't imagine it has ever been apart. It appears to be the exact same issue your motor had. This blows a hole (pun, had to do it) in the "factory mistake" theory. Also I can't imagine the motor was manufactured "throttled down" to a lower horsepower but still marketed and sold as a 35 hp motor. I would love to hear any other ideas you have since you posted the video. Also I'm tempted to out it back together with the small opening, assuming that this was designed this way (to develop more vacuum, or???). Am I making a huge mistake? Keep up the great videos!
@@eriksanders2032 All replacement parts I could find had the larger diameter bore in them. Kodi swapped his out with the larger diameter too. I finally took mine to my buddies shop and he milled the hole larger. I am working on getting everything back together (honed cylinders, new piston rings, etc). I will post my results back on here when I am done. Only discouraging part is I bought the motor as is (not running), so I have no way to know if my changes make an improvement or not.
I just picked up an 82 35hp Johnson with this issue. I went to rebuild the carb knowing this motor has been sitting for many years, probably no hours. I noticed the small port and did some research, finding the superceded part numbers. 140psi in both cylinders. I picked up the new manifold and electric start from ebay. You said you used the original reeds, would there be any reason not to? Any upgrade worth doing while I'm in there? I plan on running this motor for the next many years 😊
could I please ask you a question,, I have an old 1977 Johnson 140hp outboard motor its a "TX engine number?" and the VRO pump is a bit sick,, so I wont to take this VRO pump off and pre mix in the fuel tank,, as it is not very hard for us "old fart's" (who learned how to do real math's at school in our head's!) to work out how much oil we need to put into the petrol can/tank to get the right mix! (and all without a PP3 battery in sight!),, now I have an electric fuel pump that can deliver 20 gallons an hour @ 65psi,, so to my question! ,, The fuel quantity should be plenty for this engine!,, But would my electric fuel pump be at too high a presser as a fuel pump on this engine?,, the only information I have is, that this engine need's to have a minimum fuel presser of 2 psi,, on both top carbs at full throttle?,, no mansion of flow rate's or maximum presser's!,, and I have no clue as to what presser that VRO fuel pump pushes out! can you offer any information that would help me out,, or should I just use the engine as an anchor! thanks mike
I agree with your assessment....Factory screw up, never ran right, left in a barn somewhere, which is why it looks so nice.... There were some low horsepower engines that used an intake with a small opening, but that one is off center like you say. There are so many variations on this basic engine series, kind of hard to know where that manifold could have come from/what it was meant for. But, like you say, that powerhead is original, and there was no evidence that the intake had been messed with, so I'm convinced this engine came from the factory this way. Unfortunately, this begs the question, how the heck did it ever pass the factory tank test..... Nonetheless, your customer has lucked out, probably got this low hour great engine for next to nothing, and your great eyes fixed it quickly....
Hey Kodibass! I couldn't possibly make this up. But only one day after seeing your video here--"yesterday" at the time of my writing this comment--this happened to me. I swear, your video cursed me! The needle point on my slow speed valve has lost its adhesion and slips cleanly out of the collar. I'm guessing it was originally press fit at the factory, but I'll be damned if I can explain how it came loose. I posted a video to show it off. At that moment, I didn't think it would be related to a flooding issue I was investigating. But in the few minutes since, and after studying the 2 pieces, I'm having second thoughts. Could you take a look and tell me if this is common in your shop? I don't have a press to refit the point. Considering solder. Here's a link to the video...and thanks in advance! ua-cam.com/video/mzx7IT1k9U8/v-deo.html
Just got one down from the family attic which has sat for 39 years. It will only have had a couple of outings. At least I have learnt one thing, if I see a silly, small off-centre hole in the carb mount I know what to do.
Youthink that intake is off of a 6 and a haft hp motor? I have a 83 35 johnson that its manual shift but i cannot figure out ware the neutral switch bolts up at because there is not 1 on it. Can u tell meware it goes and what it looks like?this motor was converted from a steering weel long shaft to short shaft and manual shift. I cannot find ware it bolts up at and dont no whats it looks like?can u help me sir? Thank you Eugene
I have come across this twice, one Johnson one evinrude. Both engines were 1982 35 hp motors. Both engines had the large bore carb. Both engines ran extremely well but ran even better after enlarging the opening, made a huge difference on acceleration. One of them is mine and the other was my best friends and both still in operation. I also have tried to find out what was going with the 82 35s and found somebody asking the same question on a outboard forum and there's was also a 1982 so didn't pursue it any further just figured that's what they did that year. The funny thing is both those engines ran good before I enlarged the intake the big difference I noticed was the acceleration but the top speed on mine was about the same but it has a outboard jet lower so it's kinda hard to tell .
Perhaps it was a display engine in a dealership moons ago and they robbed the intake off for a customer and put an incorrect one back on. “And there’s yer dinner “.
All 2 cycle motors smoke as they burn the oil with the gas in the cylinders. Some say Amsoil brand oil will reduce the smoke to some degree. I say a smokin 2 stroke is a happy 2 stroke. kodibass
Need HELP I have a 35hp 1983 Johnson J35ELCTS that falls on it`s face. carb was rebuilt. It has the right intake.lol compression 150 each. iF REEDS WERE BAD I WOULD NOT HAVE COMPRESSION RIGHT? Also new fuel pump. Now the center tube going though the body leans on 1 side of outer tube. Is that normal? Also has 1 new coil. Could the red plug harness be the issue?
Not enough info to provide theories. But if you define dirty reeds or plate as 'bad", then that won't necessarily leak compression. I've cleaned plenty of reeds and plates that were sticking due to whatever buildup. So those reeds would still seal, just not open correctly. I've also seen overheated reeds that were too stiff to open all the way, but were still flat enough and not cracked, thus sealing. It is the warped or broken leaves that leak compression. So I don't use compression tests to diagnose the intake. I trust nothing other than eyes on target.
So I should get my last gasket this week and be able to give my 35hp '82 that had this problem a try.. I swapped the small hole manifold for a full sized one.. Since that motor has been running like that since '82, do you recommend any fuel additives to clean it out inside? Like sea foam, or marvel mystery oil, or..? I did clean the carb real good, and rebuilt the fuel pump, new impeller, hoses, thermostat.. Thanks
My way of looking at it is to mark the outline and grind it open , then run it with the original carb simply because if it is jetted properly at least that carb has taken the least abuse. Anyway good luck with the motor !..
+The Lucky Strike, I hope I got it straight'nd out, I told the owner to take it for a run & if it runs out ok, Then we can look at the other issues, Motor mounts , etc. kodi
What amazes me is no one ever noticed that for that long , you know they had to have pulled that carburetor before running the way it had. Good find and fix.
+David Gardner ' In fact the current owner did indeed take the carb off & clean it, He told me it made no difference, He never noticed the smaller hole, kodi
kodi! you who are the best ... my johnson 35 wets the top spark plug and the bottom one burns badly ... what can it be? check gasoline pump and it's ok ... spark has outside. What could it be? You already helped me before so I turn to you !!
@@kodibassInsideoutboards OK! A while ago I asked you for help because it wouldn't start and it was the meeting! so I rule that out ... then I'm going to try the carb ...
so if the intake was wrong,, being too small,,, why did you not just file the dam hole out to size?,, after all that intake was screwed up anyhow,, so you had nothing to loos in filing it out!
+Chris McCartney' Nope' I Show clearly in the video both sides of the all aluminum intake, every restrictor plate I have come across is at least centered over the intake hole, This is an all aluminum sand cast intake, Not a restrictor plate, It is also not a intake from a 20 hp, Already checked those measurements & provide them in the video. thanks kodi
@@kodibassInsideoutboards Thank you for your advice. I found a carburetor but that is not the same year with my engine. As a result, I also purchased the intake with the carburetor. I'll tell you how it will work.
30 years ago I had a car that was supposed to be a 2 litre. It blew a head gasket and we opened it up and found that it had a 1800 cc block and pistons. They admitted to a few of these "slipping" through. They replaced the block and pistons and crank etc for free and I paid the labour
@@kodibassInsideoutboards Crazy, the head of engineering personally sent me an apology letter with the free lower end. Thanks for the reply, I wish you were closer I have 3 x 9.9/15 hp johnnies I cant get near 1 is good but needs a carb rebuild. However im in Cambridge New Zealand. Question, if you knew it and I saw it immediately too, why not dremel the original intake bigger and try again, you said the carb looked perfect? Paul
@@paulharris5950 Yes' I could have enlarged the hole easily but I have many used 35 HP intakes, & I wanted to save this one as I'm still doing a bit of searching around on some boating forums looking into it's origins & applications. kodi
+Daniel Robert, That would be way out of my wheelhouse, But I have heard over in Greenland or some where in that general direction they do indeed run gasoline 2 strokers on kerosene or a kerosene mix of some sort. kodi
@@kodibassInsideoutboards It is my understanding that all Armed Forces and many Urgency agencies have those kerosene running outboards to diminish procurement issues in case of a crisis.
@@danielrobert7181 I do not know to much on the subject as I only recently heard about this, I am doing a bit of researching on the subject 4 sure, kodi
@@kodibassInsideoutboards I have a 1992, 9.9 Johnson and would like to get the bottom end resealed, would like to send it to you to get this work done.
@@kodibassInsideoutboards Oh wow LoL.... your right, oh well I sure would have liked for you to have done the work, you show so much passion working on those engines! No worries, I thank you very much and for replying.
I would put that gasket on that intake and mark it with a magic marker and drill holes inside the circle ⭕️ or some how cut the metal away to make the two match up. But I guess just changing the intake wood be the best.
Hi Kodi, I've been sick all last week and just feeling better now. Been writing down ideas for upcoming videos. So fired up and ready to get at it. My thoughts on this part is it wouldn't have passed inspection at the factory running like that. My guess is someone needed a good part and swapped it out. Then the engine was just passed along from there. I wonder what that wrong part was off of? Had to be a smaller motor and carb.
Yeah, didn't look like the intake had been messed with...Kodi would have seen chipped paint on the screws and evidence of a new gasket. But, I agree with you, how the heck did this thing ever pass a tank test at the factory....I'm guessing it was just pushed down the line, hopefully by mistake....
+Short Bus, It's not so bad if it's a fresh water motor, If it's a salt water motor, getting the powerhead off is the hardest part you do have to split the block but that's around 10 bolts or so, These bolts normally come out pretty easy . Depending on how well it comes off you might be able to reuse the intake gasket. kodi
I've run across that before with even a smaller hole in that one about the size of a dime
Did it run correctly? This one didn't run well at all, no top end. But after a new intake she was a good runner. kb
Now I want to pull the carb on my 35 Johnson to make sure I’m not missing out on some power ! 😂
+AdamJohn79, From what the boating forum folks told me & some other heavy hitters in the outboard community this may have only been a issue from 79 thru 82 35hp motors. kodi
kodibass cool, mines a 1980
Have this motor i got got on buyin it wont let me pull the pull start with spark plugs in but if i take them out it will let me pull
likley wrong spark plugs, If they R 2 long the top of the piston will hit them preventing it from turning over. kb
@@kodibassInsideoutboards QL77JC4 - Champion Spark Plug
Are they ones i have got them from a marine repair shop. Just unfortunately dont have the funds right now to have them even diagnose it thanks 🙏 🙂 ♥
They started to mill it at the factory and the mill stopped for some reason. The guy running mill pulled that manifold out and it accidentally got put into the “ready to fit” pile at the factory.
Hey kodi question,I have a 1978 25hp evinrude,if I take the carb off a 1975 35hp Johnson and put it on the 1978 25hp will I see a difference in speed ?
Yes' but make sure the intake hole is the same as that of the 35, If not you will need to enlarge the hole or change the intake to the 35. kb
@@kodibassInsideoutboards I went to marine Engine and they’re both have the exact same intake manifold, thank you I appreciate the comment
I love outboard motors so much! I started working on them, jumping from HVAC WORK to boat motors in 1988, and never looked back! I opened my shop in 1990 on the main drag in Medford, Long Island and I too had at least two motors that had the restricted hole in the intake manifold! I used to know 3 older guys who worked for Johnson and Mercury outboards,, but sadly they're all passed on now. I'm sure they could have answered the question that would solve this mystery!
My first thought was that maybe all manifolds came cast that way, and either had the small hole ~stamped~ out,, and maybe at the factory, the workers might then enlarge the hole to match the h.p. of that particular motor! Who knows?!?!?! LOL!!! Really enjoy ypur videos Kodi!!!!! Sonny.
Yep' I think about this motor from time to time, & just scratch my head. thanks kb
My limited knowledge / research of converting a 25 hp to a 35 hp. There is sailboat 35 hp that is detuned to a 15 hp. Used for torque.
I know everybody has to put their 2 cents worth in on what they think happened here. heres mine.. I tihnk it was put on by mistake at the factory assembly line. i think it was accidental.
Well the best OMC commenter on here agrees with U , as do I . kb
it took 40 years for the right mechanic to find the problem,, great job
Reguardless of the hole size of the intake manifold, the fact that the bore center is not inline with the bolts tells ya that
something is definately wrong. even if the intake was from a 10 - 15HP the bore center should be on center line of the bolt centers. this is a major screw up somewhere.
It looks to me that the casting was missloaded onto the machining process that makes the throttle bore.
I have been on the machining end of Die-Cast for several years and that is the only thing I can think of.??
By George I think you got it.
I got lucky I even noticed it, Even a blind squirrel finds a nut every now & then, haha kb
I bought a 1982 monarch 15' John boat 1542F actually and had had the same intake on the motor Thanks to this video I changed it out and bought a correct one for $25
Fantastic. glad to hear you got it. kb
That's a twin cylinder 6hp😂 both of my 35s have big holes
Yep' I knew something was up because of how clean the motor was for my area, Heck I doubt it even made 6hp or had more than 4 hours of run time. kb
@kodibassInsideoutboards ive got a 1977 Johnson 35 and a 1981 Evinrude 35. The Johnson is electric start and i like that but the Evinrude goes 12mile faster on the same boat
@@chiphood2966 Yes'' That starter / rectifier system adds a bunch of weight. However a Prop change can & will '''RECTIFY'' That Problem Mate. kb
@kodibassInsideoutboards what prop would you recommend? Out of curiosity. I say im not after speed, just reliability and efficiency but there are times i do enjoy speeding
I just had a ‘82 35hp apart that was previously running great with the same small hole intake. It was that way from the factory. Not sure why though.
my e35elcnd has the same intake
I think you may have a factory block that was put together for a market area that requires detuned engines, but during assembly to the mid-section and lower some how it got mixed up at the factory and ended up slipping out the door with US serial and model numbers. This is kinda like two headed coins that slip thru the Mints without detection.
Yep' I thought something like that took place as well. kb
Damn it take a power tool to it and while at it make it bigger than the 35 and you might get lucky 😂 mind boggling!
I replaced the intake from a junker 35 hp & it ran correctly. thanks kb
@@kodibassInsideoutboards That’s amazing! I got lucky and scored the same motor (1983) for just $50. Been sitting for years. Sprayed 2 cycle oil in cylinders, turn by hand, cleaned carb, changed fuel lines, changed fuel pump as first one was deteriorated. Cleaned started brush, changed plugs to jc4. First gas tank mixed 50:1 plus a little extra splash, and now she starts so easy and idles fine. The only thing is at 1 1/2 turn out on carb it starts easy but sneezes and dies after a few minutes. But at 2 whole turns out it starts easy and stays running. So I left it there haha. Any tips? Bear in mind this is a new hobby so I’m a rook. Lol
So that's crazy I've rebuilt so many rude and Johnson's and never seen that I just bought a 35 rude from 79 good compression good spark starts cold on first try no prob but idk if a Reed's fucked up or carbs clogged but it's goes a little less than half full throttle I'm going to pull it and clean the carb I'm going to see if it has this I'll post when I pull the carb
What did you find?
That’s the first step to machining out the intake hole of the aluminum cast someone didn’t finish. Got distracted put it on and it went to paint etc.
Get it machined the rest the way and it will work just fine.
And the reed valves?
That's exactly what I think. Years ago when I was a millwright, it was common for a component to fall from a roller bed or a bin. Workers under pressure for high quota often moved too fast to recognize it as out of place. They'd pick it up and put it back on the line, no telling how many stations it bypassed.
It's the sort of thing QC wouldn't easily catch, because true manufacturing flaws tend to result in a bulk.
@@TonyGingrich I Agree, it happens more than most people think. As a Millwright, I am sure that you have seen this more than you would have liked to.
@@timothyclingerman5430 Ha! I never miss spending days or weekends trying to find imaginary problems in machinery, all because of one defect caused by simple human error. At least once, I needlessly replaced a bearing just so that managers would get off my case and let me have my time back.
I found the same problem in my 82, 35hp Evinrude, a pain in the ass to start. Just ordered a new manifold plate hope it works....also rebuilding the carb. The motor starts but it floods constantly. I thought it was the fuel pump but the problem persisted. Lucky for me I saw your video prior to taking the carb apart thanks so much I will keep you updated
Sure hope it takes care of the problem, I still scratch my head on this one. kb
As soon as I saw the small opening in the manifold I thought....plum size hole ....omg
New sub here
Same exact motor
It's now fixed and starts up no problem
I think what you might have there is a 388584 manifold from a '77 25 horse. It may have been put on to detune the motor if it was used in a lodge. These big inch 25-35 horse motors are the same internally from '77 on and they shared the same 396788 manifold from '78 on. The '77 manifold looks like a one year only item so it might be rare and worth a fortune to someone!
Also, where is the motor made, Canada or USA?
+mumbles552, I saved it , I just want to look into it a bit more. kodi
Did you find anything out about the manifold. I have a J35elcnd and I have the same issue. Everything was like your all the paint on the bolts and edges of gaskets like it’s never been apart. Mine is part number 390655 but I can’t find which model motor it would have been installed on.
Looks like they missmachned the intake. The outline of the intake on the inside if machined to the larger dimension would appear to be right size.
+john zudans, I could have cut the hole to match the carb but I wanted to save this one & do a bit more research on it, Also I have many other correct 35 intakes in the bone pile. kodi
Could it be it was just not machined for the 35hp carb if they used the same intake casting for the twin cylinder single carbs engines
+BBL, From what i have heard from others totally possible. kodi
Ive seeen them before with the offset small hole on 20HP models.What the OMC engineers did on very limited production numbers was cut corners & put a 35HP carburetor on a 25-35 block to drastically depower it to make it a 20HP.Thats why the highspeed jets are the same number value as the 35HP. It was a cheap way to make a 20HP model probably last minute decision.The ones I have seen had the same offset small hole like yours does not many but I have seen a few and used the large 35HP gasket. Hole doesnt have to be on center fuel aircharge doesnt know the difference as long as it gets in.I know its very strange but thats how they came I thought the same thing years back.Im my humble opinion that motor still has issues running in the tank shaking like a leaf,LOLL but your getting there love your videos......................... Glenn P. .
+GFPALL62, Very interesting info, O'Yes this motor has shot motor mounts & many other issues that need tending to, But owner just wanted me to get it running well & so it will start. I'll point out to him all the other issues 4 sure. His call & bank. kodi
@@kodibassInsideoutboards Oh the mounts are bad thats a good reason for the shakes,LOL.Back in the late 1990S I rebuilt a Saildrive Zephyr 15HP a converted detuned 25-35 a strange configuration to see by the way for a gentlemans sailboat. It might of had that manifold on it too like others have mentioned but not 100% sure it was a long time ago.But anyway looking forward to the next video keep up the good work ...GlennP.
hhhhha
What are your thoughts on trying to open up the hole vs replacing the intake cover?
+JC I think either would work just fine, kodi
@@kodibassInsideoutboards Actually, you would need at least a decent bridgeport (milling machine) and the proper tooling to be able to correct the off-centered hole, then pollish/burnish the hole to spec so that Whatever is recieving into the hole is a near perfect fit. It really woulden't be worth the trouble. I am sure Tony up there would agree.
Great discovery and attention to detail.
I got an 82 off Craigslist that was practically mint except the head of a rod bolt popped off. I saw the same thing when I disassembled it and replaced it with a full hole 35. I saved everything to research just like you and also checked the jets. I originally thought someone put a 20hp power head on it. Now I’m seeing this was a 1982 thing… perhaps some strange epa crap.
You sell used Johnson evinrude parts ?
Someone fucked with so many people by doing this Haha I'm dying laughing
Kodi, I learn so much from your videos! I picked up an 82 35hp (E35ELCND) for $100 this past summer. I watched your video before tearing into my motor and was shocked to see that mine has the same small opening at the intake. It is offset from center, and smaller than the carb opening and smaller than the gasket. The bolt heads holding the intake are factory fresh so I can't imagine it has ever been apart. It appears to be the exact same issue your motor had. This blows a hole (pun, had to do it) in the "factory mistake" theory. Also I can't imagine the motor was manufactured "throttled down" to a lower horsepower but still marketed and sold as a 35 hp motor.
I would love to hear any other ideas you have since you posted the video. Also I'm tempted to out it back together with the small opening, assuming that this was designed this way (to develop more vacuum, or???). Am I making a huge mistake?
Keep up the great videos!
Seth Cook I have the same issue and can’t find any info on it either
@@eriksanders2032 All replacement parts I could find had the larger diameter bore in them. Kodi swapped his out with the larger diameter too. I finally took mine to my buddies shop and he milled the hole larger. I am working on getting everything back together (honed cylinders, new piston rings, etc). I will post my results back on here when I am done. Only discouraging part is I bought the motor as is (not running), so I have no way to know if my changes make an improvement or not.
I just picked up an 82 35hp Johnson with this issue. I went to rebuild the carb knowing this motor has been sitting for many years, probably no hours. I noticed the small port and did some research, finding the superceded part numbers. 140psi in both cylinders. I picked up the new manifold and electric start from ebay. You said you used the original reeds, would there be any reason not to? Any upgrade worth doing while I'm in there? I plan on running this motor for the next many years 😊
could I please ask you a question,, I have an old 1977 Johnson 140hp outboard motor its a "TX engine number?" and the VRO pump is a bit sick,, so I wont to take this VRO pump off and pre mix in the fuel tank,, as it is not very hard for us "old fart's" (who learned how to do real math's at school in our head's!) to work out how much oil we need to put into the petrol can/tank to get the right mix! (and all without a PP3 battery in sight!),, now I have an electric fuel pump that can deliver 20 gallons an hour @ 65psi,, so to my question! ,, The fuel quantity should be plenty for this engine!,, But would my electric fuel pump be at too high a presser as a fuel pump on this engine?,, the only information I have is, that this engine need's to have a minimum fuel presser of 2 psi,, on both top carbs at full throttle?,, no mansion of flow rate's or maximum presser's!,, and I have no clue as to what presser that VRO fuel pump pushes out! can you offer any information that would help me out,, or should I just use the engine as an anchor! thanks mike
I agree with your assessment....Factory screw up, never ran right, left in a barn somewhere, which is why it looks so nice.... There were some low horsepower engines that used an intake with a small opening, but that one is off center like you say. There are so many variations on this basic engine series, kind of hard to know where that manifold could have come from/what it was meant for. But, like you say, that powerhead is original, and there was no evidence that the intake had been messed with, so I'm convinced this engine came from the factory this way. Unfortunately, this begs the question, how the heck did it ever pass the factory tank test..... Nonetheless, your customer has lucked out, probably got this low hour great engine for next to nothing, and your great eyes fixed it quickly....
Hey Kodibass! I couldn't possibly make this up. But only one day after seeing your video here--"yesterday" at the time of my writing this comment--this happened to me. I swear, your video cursed me!
The needle point on my slow speed valve has lost its adhesion and slips cleanly out of the collar. I'm guessing it was originally press fit at the factory, but I'll be damned if I can explain how it came loose.
I posted a video to show it off. At that moment, I didn't think it would be related to a flooding issue I was investigating. But in the few minutes since, and after studying the 2 pieces, I'm having second thoughts. Could you take a look and tell me if this is common in your shop?
I don't have a press to refit the point. Considering solder. Here's a link to the video...and thanks in advance!
ua-cam.com/video/mzx7IT1k9U8/v-deo.html
Just got one down from the family attic which has sat for 39 years. It will only have had a couple of outings. At least I have learnt one thing, if I see a silly, small off-centre hole in the carb mount I know what to do.
I have 1981 evinrude it has large hole, been an awesome motor!
Hey Bob go buy a 20hp and I will get u the parts to make it a 35 Monday..
Somebody was mad at the company a disgruntled worker?
Youthink that intake is off of a 6 and a haft hp motor? I have a 83 35 johnson that its manual shift but i cannot figure out ware the neutral switch bolts up at because there is not 1 on it. Can u tell meware it goes and what it looks like?this motor was converted from a steering weel long shaft to short shaft and manual shift. I cannot find ware it bolts up at and dont no whats it looks like?can u help me sir? Thank you Eugene
I have a 1982 j35rcnd with intake part number 390655 but mine isn’t restricted like this one. I wonder if it was just a mess up from the factory.
Winner winner chicken dinner.. I just got a 82 35hp, removed the carb, and guess what..
I have come across this twice, one Johnson one evinrude. Both engines were 1982 35 hp motors. Both engines had the large bore carb. Both engines ran extremely well but ran even better after enlarging the opening, made a huge difference on acceleration. One of them is mine and the other was my best friends and both still in operation. I also have tried to find out what was going with the 82 35s and found somebody asking the same question on a outboard forum and there's was also a 1982 so didn't pursue it any further just figured that's what they did that year.
The funny thing is both those engines ran good before I enlarged the intake the big difference I noticed was the acceleration but the top speed on mine was about the same but it has a outboard jet lower so it's kinda hard to tell .
Didn't see anyone ask this yet.. I saw it running in the bucket, but how did it perform on a boat? Run like a normal 35 with the bigger hole?
Perhaps it was a display engine in a dealership moons ago and they robbed the intake off for a customer and put an incorrect one back on. “And there’s yer dinner “.
Do you have a carb for a 1981 johnson 35hp
Very Bizarre 👀
Part made in China, to a high Chinese standard
It was built on a Monday or a Friday.
Wow, how did that motor pass in QC? Or is there any QC?
Lmfao this shit is funny
Just picked one of these up, smokes just as bad as this one. How do I fix that, my old E10RE0E evinrude didn’t smoke anywhere near this bad lol
All 2 cycle motors smoke as they burn the oil with the gas in the cylinders. Some say Amsoil brand oil will reduce the smoke to some degree. I say a smokin 2 stroke is a happy 2 stroke. kodibass
Need HELP I have a 35hp 1983 Johnson J35ELCTS that falls on it`s face. carb was rebuilt. It has the right intake.lol compression 150 each. iF REEDS WERE BAD I WOULD NOT HAVE COMPRESSION RIGHT? Also new fuel pump. Now the center tube going though the body leans on 1 side of outer tube. Is that normal? Also has 1 new coil. Could the red plug harness be the issue?
Not enough info to provide theories. But if you define dirty reeds or plate as 'bad", then that won't necessarily leak compression. I've cleaned plenty of reeds and plates that were sticking due to whatever buildup. So those reeds would still seal, just not open correctly.
I've also seen overheated reeds that were too stiff to open all the way, but were still flat enough and not cracked, thus sealing.
It is the warped or broken leaves that leak compression. So I don't use compression tests to diagnose the intake. I trust nothing other than eyes on target.
So I should get my last gasket this week and be able to give my 35hp '82 that had this problem a try.. I swapped the small hole manifold for a full sized one.. Since that motor has been running like that since '82, do you recommend any fuel additives to clean it out inside? Like sea foam, or marvel mystery oil, or..? I did clean the carb real good, and rebuilt the fuel pump, new impeller, hoses, thermostat.. Thanks
Check reeds
My way of looking at it is to mark the outline and grind it open , then run it with the original carb simply because if it is jetted properly at least that carb has taken the least abuse. Anyway good luck with the motor !..
Yep that would work just fine, I have so many intakes I just switched to the proper one. kodi
Maybe it's one those detuned Alaskan river motors
+ms, I have no idea, read the comments all kinda ideas about it, kodi
Good find, must of been a manufacturer screw up that was never pick up
+JB, one of the BEST OMC, gurus on YT, agrees with U. kodi
5 o'clock on a friday..😆
Yep that’s just not right intended for something or not. Good eye!!! 😳
+The Lucky Strike, I hope I got it straight'nd out, I told the owner to take it for a run & if it runs out ok, Then we can look at the other issues, Motor mounts , etc. kodi
What amazes me is no one ever noticed that for that long , you know they had to have pulled that carburetor before running the way it had. Good find and fix.
+David Gardner ' In fact the current owner did indeed take the carb off & clean it, He told me it made no difference, He never noticed the smaller hole, kodi
Omc produced a 14 hp from the 31.8 ci powerhead.Possible its a 14 hp intake?
+tootum I think that would be to old to match a 1982. kodi
kodibass my mistake the one I was thinking of had a 9.9/15 powerhead and 25 lower.1988/89.
kodi! you who are the best ... my johnson 35 wets the top spark plug and the bottom one burns badly ... what can it be? check gasoline pump and it's ok ... spark has outside. What could it be? You already helped me before so I turn to you !!
+SH, If you mean wet with gas/oil (fowling) & U have good spark? most likely a carburetor issue, If you mean wet with water, Head Gasket issue. kodi
@@kodibassInsideoutboards OK! A while ago I asked you for help because it wouldn't start and it was the meeting! so I rule that out ... then I'm going to try the carb ...
so if the intake was wrong,, being too small,,, why did you not just file the dam hole out to size?,, after all that intake was screwed up anyhow,, so you had nothing to loos in filing it out!
+mt, Because I have about 30 or 40 more on hand, kodi
kodibass
Lol 🙄
Restricter Plate !
+Chris McCartney' Nope' I Show clearly in the video both sides of the all aluminum intake, every restrictor plate I have come across is at least centered over the intake hole, This is an all aluminum sand cast intake, Not a restrictor plate, It is also not a intake from a 20 hp, Already checked those measurements & provide them in the video. thanks kodi
Hi. I would like to convert from 25 hp to 35 on a Evinrude engine made in 1988. Can you help me with data?
+ GO, Your convert is simple. Find a carburetor from a same year 35 hp , bolt it on & you R good to go. It is that simple on your motor. kodi
@@kodibassInsideoutboards
Thank you for your advice.
I found a carburetor but that is not the same year with my engine. As a result, I also purchased the intake with the carburetor. I'll tell you how it will work.
@@gabiraptor Thank u mate,, This is All a learning curve 4 all of us,, 4 sure, Pls post your findings 4 all of us,, thank-u kodi
30 years ago I had a car that was supposed to be a 2 litre. It blew a head gasket and we opened it up and found that it had a 1800 cc block and pistons. They admitted to a few of these "slipping" through. They replaced the block and pistons and crank etc for free and I paid the labour
+Paul Harris, Dam but that was pretty stand up on their part. kodi
@@kodibassInsideoutboards Crazy, the head of engineering personally sent me an apology letter with the free lower end. Thanks for the reply, I wish you were closer I have 3 x 9.9/15 hp johnnies I cant get near 1 is good but needs a carb rebuild. However im in Cambridge New Zealand. Question, if you knew it and I saw it immediately too, why not dremel the original intake bigger and try again, you said the carb looked perfect? Paul
@@paulharris5950 Yes' I could have enlarged the hole easily but I have many used 35 HP intakes, & I wanted to save this one as I'm still doing a bit of searching around on some boating forums looking into it's origins & applications. kodi
Man I want to get my evinrude on the water! I can't find a lower end or gears anywhere :(
Post up make, model and HP. we might be able to help.
@@timothyclingerman5430 thanks for the reply. I ended up rebuilding it. Then sold it. Lol
On to the next one.
well done doctor
+Victor Remick, Thank you for the kind words. kodi
O.K., here is my long shot. Could it have been designed to run on another fuel than gas ?
+Daniel Robert, That would be way out of my wheelhouse, But I have heard over in Greenland or some where in that general direction they do indeed run gasoline 2 strokers on kerosene or a kerosene mix of some sort. kodi
@@kodibassInsideoutboards It is my understanding that all Armed Forces and many Urgency agencies have those kerosene running outboards to diminish procurement issues in case of a crisis.
@@danielrobert7181 I do not know to much on the subject as I only recently heard about this, I am doing a bit of researching on the subject 4 sure, kodi
Good diagnosing, what's a good way to get in contact?
Just like you , just did kodi
@@kodibassInsideoutboards I have a 1992, 9.9 Johnson and would like to get the bottom end resealed, would like to send it to you to get this work done.
@@baldoh.6897 It would not be cost effective as I live 200+ miles off the Alaskan mainland. kodi
@@kodibassInsideoutboards Oh wow LoL.... your right, oh well I sure would have liked for you to have done the work, you show so much passion working on those engines! No worries, I thank you very much and for replying.
I would put that gasket on that intake and mark it with a magic marker and drill holes inside the circle ⭕️ or some how cut the metal away to make the two match up.
But I guess just changing the intake wood be the best.
I could have told you the problem... Its a 1982 35 EVINRUDE
Hi Kodi, I've been sick all last week and just feeling better now. Been writing down ideas for upcoming videos. So fired up and ready to get at it. My thoughts on this part is it wouldn't have passed inspection at the factory running like that. My guess is someone needed a good part and swapped it out. Then the engine was just passed along from there. I wonder what that wrong part was off of? Had to be a smaller motor and carb.
+Tim's Workshop TJY, Glad to hear you are feeling better, I;m still not sure what to think of this 82 35hp
Still looking into it a bit 4 sure. kodi
After looking at the other motors on line. I think that's just a defective part from the factory.
Yeah, didn't look like the intake had been messed with...Kodi would have seen chipped paint on the screws and evidence of a new gasket. But, I agree with you, how the heck did this thing ever pass a tank test at the factory....I'm guessing it was just pushed down the line, hopefully by mistake....
How bad a job is a 73 evinrude 25 lower crank seal, this thing wont idle
+Short Bus, It's not so bad if it's a fresh water motor, If it's a salt water motor, getting the powerhead off is the hardest part you do have to split the block but that's around 10 bolts or so, These bolts normally come out pretty easy . Depending on how well it comes off you might be able to reuse the intake gasket.
kodi