'03 Johnson 90 starting problem

[gibbsb]

On about every 5-10 starts, all I get is a click. It might take 3 turns of the key to get it to start normally. I have cleaned and tightened all connections that I can get to without removing lower side cover. I have cleaned and lubed all plug in connectors and relays. Motor has 170 hours on it. It there a common failure on these motors that would cause this? Boat is 350 miles from home on a boat lift and I would like to fix it without hauling it home and tearing it apart. BAttery fully charged.

Any ideas?

Thanks in advance,

Barry

 

[tashasdaddy]

Re: '03 Johnson 90 starting problem

could be several things, bad ignition switch, bad or misadjusted neutral switch,
solenoid starting to fail, dead spot on the starter windings. is the boat use in fresh or salt water? also could be a bad battery cable, check for swelling of the cable. if they get nicked they deteriorate from the inside out.

 

[JB]

Re: '03 Johnson 90 starting problem

My money is on failing solenoid or dead spot on starter motor commutators.

 

[Marz-Bar]

Re: '03 Johnson 90 starting problem

I have an 02 Johnson 90hp that did the exact same thing. Got to the point where it wouldn't turn over at all (luckily i was over my favorite fishing spot ha ha) had starter rebuilt by the local starter and alternator shop. Has worked well since. Not sure what they did to it, the guy who worked on it was not there when i picked it up.

 

[HighTrim]

Re: '03 Johnson 90 starting problem

Voltage drop testing will indicate a weak link in the wiring or a solenoid or starter problem.

Try turning the bendix a 1/4 turn and trying again. Could be commutators as suggested.

 

[gibbsb]

Re: '03 Johnson 90 starting problem

I guess there's no easy solution but to take the lower side cover off so I can get to all the wiring and do the proper tests. I was just hoping to get a consensus like all those solenoids are junk or all the ignition switches fail in the first 200 hrs. I'll be back at the coast in May and will take all my tools! Of course, with the cover off, it will never fail!

Thanks,

Barry