Control box issues... rebuild or replace?

[ftl900]

After a short and abortive maiden voyage, we brought our POS pontoon back home- I had little or no throttle in forward, and it only idled in reverse.

At the boat launch, the boat started and idled a bit but wouldn't run over a minute or so. After taking it home, I couldn't get it to start at all. No spark at the plugs, but the battery was very low by then so I'm charging it.

The start/fast idle lever didn't seem to affect anything at all. Rentprop1 came over and showed me where things in the motor were supposed to move- the timing advance. With the control box open, I verified that the lever doesn't affect anything anywhere- it doesn't move the cable at all.

I also found a small part that had broken inside the control box, with the screws broken and separated from its nylon mount. I didn't 't get the throttle lever off to troubleshoot the timing advance lever and why it wasn't moving the cable, but having the control unit apart, I wonder if it will be more difficult to replace parts and rebuild it, or try to replace the control box completely.

In the diagram below, #41 is the broken piece- it's broken off its screw mounts. I considered a marine-tech repair for a second, and discarded the idea as foolish and counterproductive.

The spacer (#15) fell out, and is broken- I'm not sure if it serves a purpose or not.

I have the circle/cog part #23 removed, but the entire throttle control arm is still attached, and I hesitate to take anything apart any farther. I'm to the point of getting in over my head as far as reassembly.

 

[NoKlu]

Re: Control box issues... rebuild or replace?

If it's an older control it might be worth the money to just replace it to eliminate any trouble in the future. Getting stuck on the water a few miles from home is a pain in the rear.

 

[ftl900]

Re: Control box issues... rebuild or replace?

That's kind of my thinking as well- my concern there is finding a compatible replacement with the timing lever and all. I haven't seen anything that looks like this one. It says OMC on the throttle lever side pivot point.

I don't have enough boat experience to know what will fit and what will cause me more grief and headaches.

 

[Home Cookin']

Re: Control box issues... rebuild or replace?

get another one, even a used one from a boat junkyard if it needs to match an older motor. You'll spend more time trying to find the parts to replace the broken ones.

 

[ftl900]

Re: Control box issues... rebuild or replace?

Yeah, it's for an 89 Johnson 60, so it qualifies as an older motor.

I'll hit a couple of local places this weekend and see if I can find something similar.

 

[ftl900]

Re: Control box issues... rebuild or replace?

OK, so riddle me this - how do I know what will fit as a replacement for my control box?? It's on my Johnson 60 but says OMC on the controls. The only thing I've seen with a warm-up lever (like mine) is $200 and is made for newer motors and requires an additional $109 adapter for it.

I can't spend $300 to replace the control box, but I don't know enough to tell if a control box will work in place of mine unless I happen upon an exact replacement that's exactly like mine.

 

[gene8084]

Re: Control box issues... rebuild or replace?

Try calling the guys at amarket (800) 349-2628 and describe what you have. They've got a couple controllers which fit OMC & Merc. You may come up with a match.​

 

[grahamh]

Re: Control box issues... rebuild or replace?

I'd try to find a used one, I would think individual parts would be very hard to find.

I did take apart and fix an identical one on my friends boat, we had two old boxes and were able to combine the pieces to make one good one, and it's still working fine.

Don't be intimidated by the exploded diagram, it's a lot simpler in real life.

 

[ftl900]

Re: Control box issues... rebuild or replace?

Yeah, it's not terrible once it's apart, but I think the word 'exploded' applies more to the innards than to the diagram. I had pieces rolling across the floor... oops, excuse me, across the deck.

The diagram helps a bunch, but it's not enough. The warm-up lever is not actuating the cable - it moves freely with no drag, and the assembly is behind the throttle lever assembly. I can't seem to get that off, so I can't determine why the warm-up lever isn't functioning- don't know if it's a cable or lever or other issue. I'd love to find another similar box and cannibalize it to fix mine, or a good working one and replace mine altogether.

I guess part of the problem is working long hours and having little time to GO to boat part places while they're open. I found Glenn's Boats in Crystal River but haven't been able to get there while he's open. Yet.