1960? Johnson 40 serial number RDS-22

[b717doc]

Hello everyone,
Just registered, and super glad I found this site....I simply 'Googled" my motors serial number and here you were...GREAT. I bought the boat a few years ago, a 13 foot runabout with the Johnson 40 hp on it, serial number RDS-22. I know absolutely nothing about outboard motors, but have managed to work my 1 hour of working on it to 1.5 hours of use...Seems like I work on it more than I get to use it...Either way, I cant afford another boat, and don't think I want to "give" it away, like the guy did that I bought it from...boat, motor and trailer all for $500...The time before the last that I took it out, it ran great, not too fast, but served our purpose. (about 25 mph). The last time I tried to take it out, the accelerator handle felt like it was binding (again), but this time, something under the flywheel either came out of a slot or something, or broke, don't know which, as I can't seem to get the flywheel off. I dont have the super giant sized flywheel puller, which I guess I'll have to buy, unless someone has some ideas. Don't have a book, can't find a book on e-bay..Any ideas would be appreciated...Is this motor a general PITA, or worth working with? I rebuild classic british bikes for fun, so It cant be too hard...

 

[K.B]

Re: 1960? Johnson 40 serial number RDS-22

Welcome to I-boats!

Great site w/tons of info from great folks!

'60 Johnson. From what I gather, it is not Selectramatic if you're "twisting" the handle and not much speed. That's a plus for the lower end situation but makes me think, also, it is not elec. start, which would be a minus for ME; but yes, it is a good motor for the price if it has good compression, a new water pump impeller, and coils. If not they need immediate attention in order to keep it from becoming an anchor!

You could find elec. start items at local boat repair/'net/etc. if they are needed.

Don't be skeered!! It's worth it if you like boating/piddling/restoring. Good motors!

 

[F_R]

Re: 1960? Johnson 40 serial number RDS-22

You do not need a "super size" puller. In fact you should NOT pull on the outer rim of the flywheel as that will destroy it. What you need is a harmonic balancer puller (auto parts store), and three 1/4-20 Grade-8 bolts. They go into the holes where the recoil starter ratchet is attached. Then pull away. It is HARD to got off, so pull hard..it will come with enough force.

When reinstalling it, the tapers must be clean and dry and the nut properly torqued to specs. Failure to do this will destroy the motor. You really, really do need a manual. Cheapest favor you can do yourself if you are going to be doing the work yourself.

 

[JB]

Re: 1960? Johnson 40 serial number RDS-22

Get the Johnson Service Manual, 10th Edition, from www.kencook.com.

It will save you many bux and headaches.

 

[asdasc]

Re: 1960? Johnson 40 serial number RDS-22

Go to the engine FAQ and read the one 'Awakening a sleeping outboard'. Although your hasn't been just sitting, there are a few must-do things, just because all the Johnson 10-40Hp motors need it from that vintage.

- Replace the impeller: very easy and cheap
- rebuild the carb: very easy and cheap
- Pull the flywheel and replace the coils, points, condensors: not so cheap, but most of the old coils are either failed, or will as soon as you hit the water on the most perfect day of the summer. The good news is that the newer coils will last a lifetime. The condensor and points are cheap, and since they are a pain to get to, why not just replace them.

After that, if you tune the carb per the instructions on the FAQ, it will purr like a kitten. You really do have one of the best outboards available. Very tough, great running, and parts are readily available.

you can get all the parts you need for a fair price right here on iBoats, too.

Good luck with it!

 

[tashasdaddy]

Re: 1960? Johnson 40 serial number RDS-22

tell us some more about how you have it set up. is it set up to use the tiller, or remote controls and steering wheel? electric start? have you check for spark on both cylinder?, cleaned and rebuilt the carb? you may find the the coils are cracked when you get the flywheel off.

full report back to us.

PULLING FLYWHEEL

you need a harmonic balancer puller, you need 3 - #8 harden bolts, that fit the 3 holes in your flywheel. standard hardware store bolts will strip out, causing more problems. loosen the flywheel nut, leaving it on so it protects the thread. thread the bolts in 7/16 of an inch. then tighten the puller, adjust so it has a straight pull. now tighten the puller, rap the center bolt with a hammer, then tighten some more. you may have to let it sit over nite, and repeat in the morning. this is a compression fitting, it will eventually POP!!. do not loose the woodruff key that goes in the groove of the flywheel and the crank shaft. then installing the flywheel, it has to be totally clean, no oil, woodruff key in place. then torque the nut to the specifications for your particular motor. if you do not do this, the woodruff key with shear, and you will be repeating these steps.

 

[b717doc]

Re: 1960? Johnson 40 serial number RDS-22

Yes, it has an electric starter, and yes it has "forward controls", mounted on the right side of the boat by the drivers seat, and they too are labeled "Johnson". There's a red lever for an accelerator, and a black lever for forward, neutral, and reverse. I have to service the lower unit after every trip to the lake, because the "boat house" over in town says its easier than trying to replace the o-ring seal that keeps water out of there. Will do all of the above between now and the next few weeks. As far as being "set up", I really have no idea, all I know is it's mounted to the back of the boat, and has a chrome prop on it...Carb gone through, but not "rebuilt", and It has a good blue spark at both plugs, and good compression, last I checked. All done with all 3 of my Triumph motorcycles, so now it's boat motor time....Wish me luck.

 

[tashasdaddy]

Re: 1960? Johnson 40 serial number RDS-22

disconnect your throttle cable at the motor, see if the the handle still binds, could be cable going bad. then move motor throttle linkage. have you had the lower unit pressure tested, to see where it is leaking?

 

[b717doc]

Re: 1960? Johnson 40 serial number RDS-22

Man, you guys are GREAT.... Went to AutoZone, picked up the Harmonic balancer puller for a deposit of $96, had the flywheel off in no time (took alot of "sequential" tightening and tapping). Back to AutoZone for the refund, no problem at all....However, things not looking good under Mr. Flywheel. One of the red coils has serious chafing from something, and will have to be replaced. Points look okay, but will be replaced as well. Metal "arc" thing that plug wires go into is completely separated from underneath timing plate, looks like a couple of countersunk screws missing that held it on, (not sheared off, thank goodness). Can't afford the $76 it costs for the manual, unfortunately, but will not do anything detrimental that I can't reverse. Looks pretty straitforward to me...Impeller previously replaced. Will have to cowl her back up for now until I get more time off work...Thanks again...Doc

 

[Willyclay]

Re: 1960? Johnson 40 serial number RDS-22

Just sent you a Private Message

 

[shipleyman]

Re: 1960? Johnson 40 serial number RDS-22

Brand new here and just picked up one of these same motors. Doesn't run (locked up) and I'm going to try and rebuild it. Never rebuilt an outboard before so I'm wondering if it's worth it. Any advice/thoughts would be appreciated. I'll be keeping my eyes peeled for relevant posts here!

 

[asdasc]

Re: 1960? Johnson 40 serial number RDS-22

Hi Shipley, you should probably start your own thread, but I wanted to reply. When you say 'locked up' many things could cause that. If the powerhead is locked up, that is really bad and probably not worth rebuilding. Search around on eBay and you can find another powerhead. I would pull the plugs and pull the lower unit. If you still can't get it to turn over, lay it with the plug holes up and pour some Marvels Mystery Oil in each hole, then let it sit a few days. Try and move it again with a rope (not the starter rope, you might break the little ratchet part) or with a wrench on the flywheel nut. See if you can get it rocking back and forth a little. Many times this works great. I had one that I thought was frozen and after a week of soaking and pouring oil in the cylinders I pulled the lower unit to find that it was locked up, not the power head.

Good luck with it and keep us posted.

 

[tx1961whaler]

Re: 1960? Johnson 40 serial number RDS-22

Brand new here and just picked up one of these same motors. Doesn't run (locked up) and I'm going to try and rebuild it. Never rebuilt an outboard before so I'm wondering if it's worth it. Any advice/thoughts would be appreciated. I'll be keeping my eyes peeled for relevant posts here!

Whatever you do, don't try to force anything. If the rings are rusted, they'll break off if you get rough with it.

 

[badreves]

Re: 1960? Johnson 40 serial number RDS-22

try a streering wheel puller i have worked on a few boat motor and it works