Help needed with hooking up 2003 Johnson 50 controls

[lakelover]

I have this question posted in my resto thread, but I thought I might also put it here too in hopes of getting a little more exposure with the J/E experts...

My outboard is a 2003 Johnson 50 (J50PLSTD)...I have a brand new BRP control ready to hook up but need the throttle/shift cable and wiring harness. I also have the combination Tach/System Check gauge.

How do I measure for the throttle/shift cable? I found these, but what length?? http://www.iboats.com/Johnson-Type-479-Control-Cables/dm/*******.292844927--**********.024350968--view_id.250882

Also, I'm having trouble locating a wiring harness for connecting the control to the motor & system check gauge, or more specifically, I don't really know what I'm looking for. I found a 10' extension cable (part # 0176334) with 3 plugs on each end.

Will that do it? Looks like it might be the animal.

A total novice in this area, any suggestions will be appreciated.

 

[Woodonglass]

Re: Help needed with hooking up 2003 Johnson 50 controls

I found this if it will help...

http://www.go2marine.com/productcenters/teleflex/teleflexCableMeasurements.shtml

 

[lakelover]

Re: Help needed with hooking up 2003 Johnson 50 controls

Thanks, Wood, that will help a lot. A lot of life details getting in the way right now, so I haven't really had time to dive into the issue, but this will be a good start.

 

[hidef]

Re: Help needed with hooking up 2003 Johnson 50 controls

The cable drawing you posted is correct. Your engine uses the modular plugs very easy to hook up they only go one way. The warning horn is external to the controls I tucked mine up under the dash where it will stay dry on my Jet.

 

[lakelover]

Re: Help needed with hooking up 2003 Johnson 50 controls

Thanks for the info, hidef, and for looking in on my resto thread too.

 

[lakelover]

Re: Help needed with hooking up 2003 Johnson 50 controls

Here's another question.

On my steering connector I have what I need to connect the motor end, but need the washers and lock nut on the cable end. Is that a part I need to get from BRP? I have the part #0315077. By my best count that's a 26 thread-per-inch thread.

 

[hidef]

Re: Help needed with hooking up 2003 Johnson 50 controls

You can get the washer and lock nut from BRP or any outboard dealer for that matter. The steering end is standardized as they are all made to fit the various steering cables. I believe the threads are metric.

 

[lakelover]

Re: Help needed with hooking up 2003 Johnson 50 controls

You can get the washer and lock nut from BRP or any outboard dealer for that matter. The steering end is standardized as they are all made to fit the various steering cables. I believe the threads are metric.

Thanks again. That probably explains the odd thread count.

 

[lakelover]

Re: Help needed with hooking up 2003 Johnson 50 controls

As far as the throttle & shift cables, are they the same and I need to order two of them? As you can see, I wasn't kidding when I said I knew nothing about this. These answers and the shop manual are a big help.

 

[hidef]

Re: Help needed with hooking up 2003 Johnson 50 controls

You need to cables and they are the same. When you install them make sure the the control is in neutral and the idle lever is all the way down. Make sure the engine is in neutral and the throttle is closed. Install the cables into the controls first and then hook them up to the engine. You will need to adjust the cable ends at the engine to fit the engine.

 

[lakelover]

Re: Help needed with hooking up 2003 Johnson 50 controls

[Edit: started a different thread with a different question.]

 

[lakelover]

Re: Help needed with hooking up 2003 Johnson 50 controls

Looks like I'm missing a piece of the puzzle (or more).

I have the motor end of the 10' harness hooked up. All the wires match by color:

I don't know why the motor-end plug of the 6-wire connector has a pin in it and there are only 5 wires coming from the engine:

The only matching 2-pin connector from the oil tank fits to the warning horn:

The connectors on the front end of the 10' harness don't match up except for one of the 6-pin connectors. The triangular 3-wire connector has two female plugs coming together and the wire colors don't match; and where does the other 6-pin go?

Here's where it gets really fun. There is an 8-pin connection on the back of the tach and no 8-pin plug anywhere to be found:

I can't find anything in the shop manual about hooking it all up but this diagram, and everything else seems to be related to testing the circuits. The info that came with the control doesn't really tell and nothing came with the tach. I don't see any part listed on the BRP parts website either. No luck googling it either.

And you think I was confused before? Obviously missing something!

 

[lakelover]

Re: Help needed with hooking up 2003 Johnson 50 controls

Google helped me find my answer. This is what I need.

 

[hidef]

Re: Help needed with hooking up 2003 Johnson 50 controls

When buying a used outboard you really want the controls to come with it. Even if the controls are shot according to the previous owner because the wire harness is a pain to get. Your local BRP dealer should be a able to get the wiring harness for you and I would have thought the controls you bought would have had the harness with it.

 

[lakelover]

Re: Help needed with hooking up 2003 Johnson 50 controls

In my inexperience two years ago I didn't really realize the importance of that. I bought the motor from the boat rental business and I suppose they cut all the corners they could by reusing everything possible, that's why they wouldn't part with any controls. I tried to haggle them down from their asking price because of that but they wouldn't budge. Unfortunately they knew their outboards a lot better than I did!