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Water Test #2 Today
1996 Johnson 40hp
Changed out fuel line and bulb for new OEM.

The throttle still has a dead spot in it between 2,000rpm and 3,400rpm.
When running at 2,000 rpm's, if you slowly move the throttle forward, nothing happens and then it jumps off and runs towards 4,000rpm's.

Not a slow build anymore, so I do think I had a small air leak in the fuel line.

Also, when at 3,500 rpm similar response going down. Nothing for 1st 1" of travel on the throttle, then it drops right away to 2,000rpm.

I was playing with fast idle cable the other day with the cover off because I had not used it. I seen an electrical cable that seemed to be rubbing the throttle body cam (?). Seemed like it was preventing cam from coming back to stop position and was idling at like 1,200 rpm. I tried to push the cable over and it seemed to drop slightly but not perfect every time. I have to read more in the manual, so I didn't fool with it anymore.

I think I might have a cable interfering with the free movement of the throttle cam that is moved by the throttle cable? Once enough force is applied, it overcomes the pressure of the cable and springs forward.
Just a theory, have to read up on how the linkage works and have the wife move the throttle cable while I watch how and what moves.

I tried to observe WOT rpm. I got to 4,800rpm and about 31-32mph. It was a little choppy and had to back off before I could get a solid reading. Definietl goes fast enoughh for me, but interested to know if I have WOT rpm's closer to 5,500 as recommended.

Hoping some reading in the manual and some observations will lead to a simple solution.

Changed out last bow roller that was cut to prevent rolling by PO. Boat now slides easily off trailer and into water without any effort.

Making progress.

Doug