1971 Johnson 60hp problems

[MarineSSgt]

Johnson 60hp 1971
60ESL71C hydro electric shift
This outboard has been nothing but a pain......I'd like to replace it, but have to live with it for the time being.
Whenever I turn the key to start the motor all it does is make a "clunk" sound. At the end of last fall it was working fine. For lack of anything better to do (I have a wife and 3 daughters so I try to stay out of the house) and ease of replacement I have replaced several parts from a known good motor: amplifier assy, clipper assy, diode and lead assy, and the rectifier assy. My next step was to remove the flywheel so I could replace the coil and stator, but at this point I have no idea what I'm doing.
Can anybody give me some guidance on where to go?
Much appreciated!
-The Rookie

 

[F_R]

Re: 1971 Johnson 60hp problems

First thing first. Take your battery to an auto parts store and have it load tested. Then clean your battery cable connections. Don't just look at them, take them off and clean them shiny bright and then tighten them securely when you put it back together. These two things will fix 90% of the clunk-only starting problems.

To neglect these two things will also cause 90% of amplifier and rectifier problems.

Why do you want to replace the stator, just for funsies? The coil can be replaced without removing the flywheel. Just unbolt it from the motor and unscrew the whole thing from the distributor cap. The coil and stator have nothing to do with clunk-only symptom.

There is a distributor cap and rotor and breaker points and a anti-reverse cut-out ring under the flywheel. Probably needs service, but none of these have anything to do with the clunk-only symptom either.

You need a factory service manual if you are going to be working on that motor.

 

[MarineSSgt]

Re: 1971 Johnson 60hp problems

I already tried cleaning the cable connections....they are bright and shiny.
Last October I bought a new battery.....do you still recommend I get it load tested. It's mainly sat in my garage over the winter. I rewired the bow and stern lights on my boat and only used the battery to test the lights. I've used the battery a few other times tinkering around trying to get it to start.
You mentioned doing those 2 things will fix 90% of the clunk problem. Just out of curiosity, what is typically wrong the other 10% of the time?
Thanks!

 

[F_R]

Re: 1971 Johnson 60hp problems

Bad starter. Or a cable that is corroded inside the rubber where you can't see it. But you should see a bulge there, if that's the problem. Don't ignore the ground cable where it bolts to the powerhead. And finally, it is possible that the starter solenoid is bad, but that is much more rare than most people think. You know it is trying to work--that is the clunk you hear. If you have a voltmeter, check the voltage at the starter terminal. If it is somewhere near battery voltage and it doesn't crank, bad starter. But no voltage there, bad cable or solenoid.

Yes, have the battery tested. May have a dead cell.

 

[MarineSSgt]

Re: 1971 Johnson 60hp problems

Jeez.....Bad battery afterall......thanks a bunch for your help F_R!
Finally got her running again! Battery was only 5 or 6 months old!

 

[jameskb2]

Re: 1971 Johnson 60hp problems

Jeez.....Bad battery afterall......thanks a bunch for your help F_R!
Finally got her running again! Battery was only 5 or 6 months old!

I bet you stored it sitting on the concrete floor?

NEVER store a battery on a concrete floor. Put a piece of plywood or something under it!

(That's a myth)

 

[tashasdaddy]

Re: 1971 Johnson 60hp problems

and you did not charge it several time over the winter.