1977 115 Hp Johnson, Click, Click, Click, Fire

[saltwaterbluefish]

Outboard: 1977 115 hp Johnson

I have been tracing a gremlin in my boats electrical system that I seem to not be able to figure out.

Issue: When I turn the key, I get a click and what sounds like a sizzle.

The battery did have corrosion built up on the negative terminal, but after cleaning, a good charging and a test at an auto store the battery does not appear to be the issue. Moved on to the solenoid. It had the original equipment and with the starter unhooked I heard the click. Replaced and did not fix the problem. The starter was suffering from a pretty bad case of rust (original equipment as well) and I got a pretty good deal on a brand new one so I put a new one on. Still have the issue.

All the connections look clean and wires seem to be in good shape. I can get the motor started usually on the 4th to 5th time I turn the key. The motor runs great once it gets going, but I hate to go out on the water and not be able to get back. Last year put a new powerpack, ignition coils and rectifier as well as new spark plugs when I rebuilt the carbs a few weeks ago.

Any suggestions would be appreciated as I am lost at the moment.

 

[batman99]

My previous 1996 Force 120 engine did similar behavior. To resolve its random "click / click" problem, I:
- Replaced starters existing internal brushes. Hopefully, your new starter has NEW internal brushes.
- Bought brand new Marine battery. Previous was size 24. I replaced with next size up - size 27 (need new plastic battery box as well). re: Marine Battery 27DC-850N
- Replaced its factory thinner size battery cables with next thicker size as well. Think I bought a set of thick battery jumper cables (that where Red and Black marked) and installed (soldered) new ends of them.
- At each connection point, I applied dielectric grease (to make better contact).

After these upgrades, my Force 120 never went "click / click" again.

Hope this helps.

 

[Bosunsmate]

use jumper cables to work out which cable is bad. Water wicks up the cable and corrodes them internally under the rubber.
Start by putting a jumper from the negative to a good clean ground on the motor. And test, then keep that there and add a positive on one of the two sections of positve.... and repeat that on the other section.
Also make sure your bolts holding the starter on a clean threaded.
Yeah not getting back in is my concern always too, i use to only go out on an onshore wind

 

[Bosunsmate]

By the way if all that doesnt find the issue then you will need to replace the insulating bushings on the starter. An easy job

 

[saltwaterbluefish]

Thanks for the suggestions. Considering the new starter did not fix the issue, it must be the battery or the cable. When I get home I will start to dissect the cables.

It is funny you mention the inshore wind because that usually determines which way I go on the river

 

[Will Bark]

If your battery wires are not getting hot and are not corroded, then I would suspect the starter solenoid itself; "click, click" start sounds like solenoid internals to me. Good luck

 

[emdsapmgr]

A starter test is also needed: jump start it with a set of automotive jumper cables to a known strong battery. If it the starter cranks normally when jumped, it's ok. Have you checked the key switch?

 

[saltwaterbluefish]

Thanks Everyone for the replies. To my surprise it was a bad battery cable, which is odd since I replaced them last year and it was reading the correct voltage. Guess they don't make them like they use to. :cold: