How To: Replacing the Optical Sensor on a Johnson / Evinrude Outboard Motor 

Thanks for the help. Videos like this are a must since where I live, there aren’t many boat repair shops that will touch my Johnson motor. Hope it fixes my issue.

Thank you. It is nice that people like you post these videos for us to watch and to fix our own motors when possible. I am going to try to replace my Power Pack using your videos. I am confident seeing this I can do it. Both my local dealers want $575 to $600 dollars to do this. Again, thank you and keep up the great job.

Great video. I just saved $1300 bucks doing this myself in 30 minutes on a new power pack and optical sensor. Thanks buddy!

Hey Tim, not sure where you live... but down here there's water, water, everywhere!!! We live in a rural area and pump our own water from our well for pennies. The local aquifer is in great shape and provides bottled water for companies around the nation. But thanks for the comment and your eco-concern! I'm headed outside right now to let the kids play in the hose!!! lol

The engine should be running for a much longer time on the fuel that is in the bowls. So if you pumped the primer ball until it is firm, they should be full and the motor should run atleast a minute or two. The sudden shut off seems to point to the ignition being shut off. That engine has a timing wheel under the flywheel and not an optical sensor. I think you are on the right track with suspecting the powerpack. Keep me updated!

Same thing was happening to my 150 oceanrunner. Turned out to be the temp sensor on the port side with the two wires. I believe you can test this by jumping the wires that you have disconnected in the video and it would idle down (on the muffs it will idle around 900 when brought to heat with no back pressure on the exhaust). Both the power pack and optical sensor were replaced to try and remedy this by the previous owner.

thanks..7 years on and this saved me a labor bill that I used for the gas tank instead. :)

I was running the motor on the hose, which is cool well water. The issue I had, was that the motor bogged down under load. So while I noticed no difference in the driveway, when I tested her in the water... she ran like a monster! (Also quieter at idle.) I tend to believe that the pack was not functioning correctly. In the meantime, I sold the boat and the new owner called to tell me how well the boat runs (yes, he bought it without a sea trial!!!) Good Luck with your issues.

Would love to see you do a Link and Sync on this motor as I cannot find one person who has done that on this specific motor!

While I can't say for sure what your problem is from here, the powerpack does control a quickstart function that advance the motor to ease starting. It lasts about 5 seconds... so there could quite be a problem there. I couldn't find your video, but good luck!

Just an update on mine. It was hard starting most of the time rough running sometimes and had put itself into some kind of speed limiting. Well I replaced the temperature switches and still had some problems. Seemed to run great for a while then I thought my prop had come loose.Turns out that part of my problem is in the way the plastic in plastic throttle and spark advance mechanism works. It was not going back all the way. After I figured that out it starts better and runs smoother

I used a harmonic balance puller but had to purchase the correct size hardened steel bolts to fit the flywheel. Then I used a air impact wrench to remove it. Popped right off after that. But be careful.

Thanks for the video, I noticed before the camera overheated that after you had tightened the bolt on the timing cover that it wasn't at its original setting at 2. Was your motor out of sync/timing off? I've ordered my kit that includes a power pack, optical sensor and fresh spark plug cables. I have a 2000 Johnson 115 Ocean Pro V4. Thanks!

I have a 1995 Johnson 150 and it just stop running could it be the power pack?

Hi, I have the same motor but it has been underwater. Don't ask. The timing cover is seized onto the shaft, how do you suggest I get it off without breaking it? Plastic. Oh by the way, loved your video.

yeahh of course mine has the timing wheel "encoder" stuck and no way to take it out to replace sensor....thanks for sharing I might have to break it and order new one😵‍💫

so you replaced the optical sensor before the power pack right? I didn't see if the motor ran any better after the sensor. Was it running better? Or was the power pack the ticket to a smooth idle? I've got a similar motor to yours and would rather do these replacement than my mechanic.

I have a 1993 Johnson 200 hp on a 1993 Ranger 397V . On my last outing I was getting ready to call it a night and head back to the resort and when I go to take off the bow comes up and then it sounds like a "clutch slipping" . Its not the prop cavitating as far as I know as I have solved that 2 yrs ago with the right prop. Sounds like it could be slipping out of gear maybe. Is there such a thing as spinning a prop hub ? I did stop trying to get on plane at full throttle not knowing what the problem is but did have the drive train to pull the boat 1/2 mile to the dock.Any info is appreciated. Thanks

Good video , Im replacing my optical sensor today ...did you ever get your outboard running properly...I have a similiar issue with same motor.. I also replaced the power pack, but didnt get any positive results ....Heres to hoping it is the optical sensor...

Will a bad optical sensor cause it not To have spark on one bank? 3 cylinders have no spark at all. I already checked the shift sensor it’s not that.

What was the fix of this problem ? Power pack with optical sensor?

how did you break the timing cover bolt free, without the motor turning

I have a 115 Johnson 2 stroke that is stalling when changing from forward gear to neautral. Would changing out this sensor help my issue ?

Dear Daniel, I do have a 1993 johnson 175 hp fast strike V6, and I have the same problem shown in your video, at higher speeds works fine, but a idle it doesnt even start sometimes, and it goes to auto shutdown, I miss the other part of the video where you test the engine with the new optical sensor. I am in Chile, south America, and I am not quite sure where can I get this sensor, even worse I have not the Owner and Service manual. Also have a compression difference between cylinders, 95-115

My 150 evinrude is doing the exact thing at idle as to what this one is. Your saying when u replaced the power pack the problem was fixed?

Hi i have a 1997 johnson 150hp OIS ahd have a plroblem, left bank 2,4,6 pistons not firing. Right bank is firing good. Not pass 2,500rpm, POWERPACK, OPTICAL SENSOR? And another question cable gray and red line its for? Thanks

I wanted to see u change the power pack that could be my problem

Hey, I have the same exact motor as you. I've had it since 09. Rebuilt the carbs twice (last time was in the summer along with spark plugs). I've always had this on/off knocking. It's not the foot it's the power head. But I doubt it's the cylinder because it's not constant and doesn't show any signs to be the cylinder. It starts at around 4000rpm when the boat is in gear. Doesn't do it in idle. And it's not in a pattern it's at random and uneven when it does it. It will always do it if I go from 5000 down to 4200 until the engine slows down and the boat reaches the speed the engine does at that rpm. Any ideas? I am going to check out the power pack and make sure all my cylinders are firing. Also does your have this sneez in idle every now and then? Mine does.

man... you left the water running the whole time... I got almost to the end and had to pee so bad I couldnt finish watching.

Hello Thanks for all the video's. They have been lots of help. Im having a problem with my motor. Its a 1997 Johnson 150HP. After using the boad for about 30 min non stop the motor dies for less than a second and kick right back in. It feels like it lost power for a split second. Any idea what that could be? I did the tune up (new wires, spark plugs and coil pack) and same problem keeps happening. Any suggestions will be greatly appreciated!

Is there a way to test the optical sensor, I have power going into the sensor but nothing coming out

Hey Daniel, great videos! How did you loosen the bolt on the timing wheel so easily? How did you keep the drive shaft from turning without the piston stop tool? Help! Thanks in advance!!!

My engine is idle at 5mph do you know how to idle down these engines?

Cut water off while you fix motor.

I have a Johnson 115. It cranks ok and idles ok. Runs at slow speed ok. When you push throttle forward the motor will not go above 2000 RPM's. To this point I have changed fuel, fuel filters, spark plugs, checked wires, had carbaurators cleaned and checked, then replaced all fuel lines going between motor and fuel filters and the ones between fuel filters and fuel tank. Problem persist. Do you have any ideas what I should do next??? Thanks in advance

Help please! ... i have a 1993 Evinrude 120hp and it seems to idle ok but once i engage the throttle it struggles to go 5 mph. Seems to me that it is running on 2 cylinders instead of all 4. Any thoughts?

Sir I have a problem wick my motor is a 2001 90hp 2strokes and the have a problem the make a noise like nocking and I don't find the problem

thanks share this video

cant it be cleaned from dusty road

hey, where can I find your second video?

Hi I have the same except from with this same motor same crack in the case as well did you ever get it to work I replaced the powerpack

i have the same problem with my 90 Johnson 2002 i use the key choke to start the motor i put the wamer lever up put back down to idle it just cuts out on me dosent run smooth trying to figure it

I have a 1996 150 fast strike that the starter motor just spins but the bendix won't engage the flywheel and I can't find any videos have you ever removed the entire flywheel cover?

Leave you comments or questions here!

Hello, I have a 1999 Evinrude 175 outboard, FICHT fuel injection and it has a problem starting, and when it does start, it runs for 5 min, then I cant power up it drops down to safe mode and will stall if I full throttle, along with an engine light that comes on right before safe mode and while in safe mode. Could it be the temp sensor or optical sensor? A Marine tech said they don't make parts for this 1999 anymore and might be in trouble with it. Rich

I just did this and now my motor only works while trimmed up a little bit

Check timing on the motor and it will be erratic being able to diagnose the sensor.

I have a gt150 put a new stator and power pack. the stator is firing into the power pack but no power is coming out the power pack. I don't understand that what should I CHK next

Hey Dan. I'm trying to get the flywheel cover off my motor to access the bendix gear on the starter. To do so, I need to get the timing wheel cover off as you have done in this video quite easily. My 1/2" bolt will not come off. It seems to be turning the whole fly wheel and I can't see how to lock it or otherwise get that bolt loose. Any ideas??? Anyone?? Thx!

i ended up breaking it off. fly wheel came off no problem it was the plastic disc on top of it with the timing information on it that would not come off. a 40$ mistake for about 5cents of plastic lol

save the water lol

Hello How do u adjust the throttle cable ?

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I need someone to help me please. I have a 75 Evinrude etec engine but it just throttling no power. Whenever I gas it I don't get nothing. I put it in gear and try it and it still not powering up.

Limp Mode... Easy Dude... I's only plastic...!

So, you wasted water the whole time you did the video???

I wish you had turned the water off I had to pause it and go pee!

lucky son of a gun i cant get that timing wheel off for my life i have had penetrating fluid on it for weeks and will not come off...