Johnson 90 hp - water impeller stuck on rusty drive shaft?

[ib18]

ok, so I opened up my remote control box and tried to troubleshoot the faulty shorts in the box again to clean the electric wire terminals in the key switch. I found my kill switch wire got a bare open spot. So, I taped it up. I also extend it to outside the box so I can ground it to kill my motor when my key switch fail again. Now, my F-N-R gear handle stuck in Forward shift - bummer. I will have to open the gear switch part of the box to unstuck the gear handle.

 

[Fed]

Grounding the black/yellow wire either through the keyswitch or through the killswitch is what makes it stop so a bit of bare wire isn't stopping it from stopping. You should be testing for a bad connection of the black/yellow to ground when the keyswitch is off or the killswitch is activated.
Disconnect the control cables at the motor to sort out anything in the FNR then reconnect the motor cables adjusting to suit.

 

[ib18]

will work on the stuck remote control handle today and hopefully I get it unstuck and fix the motor wont shut off problem

 

[ib18]

so today, I found my problem when my Johnson 90hp wont shut off - bad key switch of my remote control box. I also found out my kill switch in the remote control does not work, my guess is the kill switch was not connected to the power pack, because I don't remember seeing a connection when I was testing my power pack. I built a red neck solution to force my motor to shut off by extending a pig tail out of the remote control from the red terminal. Do you think this is OK?

 

[Fed]

If the key switch is faulty then replace it.

 

[ib18]

Now, my steering cable is freeze so needs to remove the motor to clean the tilt tube again - bummer. I will order the key switch soon,

 

[ib18]

A close-up look of how to unlock a frozen steering cable under the boat steering wheel to repair it. I hammer the frozen cable out of the tilt rod to repair it. Follow alone as I repair my frozen steering cable for my Johnson 90 hp power boat.

 

[ib18]

mission accomplished, now I can steer the boat with 1 hand

 

[ib18]

today I got rid of the rust on my tilt cylinder by spraying the rust converter I bought from Advance auto. I also used the left over the paint over my rusted trailer u-bolts and the strut on my boat trailer. It look super nice now. Also replaced the power winch with manual strap winch.

 

[ib18]

https://www.youtube.com/edit?video_id=UMJIzLNdYFc

my 1982 Johnson outboard won't start again? what is your guess?
1. bad spark plugs? 2. bad carburetor? 3. bad fuel line? 4. bad power pack? 5. bad ignition coil? 6. others?

2015 is a rough boating season for me. 2014 was totally trouble free until October 2014.

https://www.youtube.com/edit?video_id=UMJIzLNdYFc

 

[ib18]

So, I tried the trick I did last year before my boating season when my motor would not start by spraying WD-40 into the carb and spark plug holes. This time it was useless. Someone asked whether I messed up my remote box when I put it back along with a very good suggestion - spary starting gas into the spark plug holes. Bingo, the truth is I did accidentally broke the "neutral starting switch" in my control box before I screw it back.

Do you think that would be the reason why my motor is not starting up and stay running? I do not think so, I thought it is more a fuel problem in the carb than the broken neutral start switch.

I will open it up later today and epoxy the switch.

What do you guys think?? part #41 is the "neutral starting switch" - it is in the middle towards the very end to the right in the remote control parts diagram picture.

http://www.*****************/parts/jo...Remote+Control

https://www.youtube.com/watch?v=d8tbI5wmwVE - Johnson 90 hp v4 - almost starting 2nd try with wd-40

 

[Fed]

Do you think that would be the reason why my motor is not starting up and stay running? I do not think so, I thought it is more a fuel problem in the carb than the broken neutral start switch.

No, the neutral safety switch will only stop it cranking over, it disables the starter solenoid.

 

[ib18]

Thanks for confirming my guess. I used starting fluid last year instead of WD-40. So silly of me. Will buy starting fluid tomorrow to start my motor. Can't wait to go boating again.

 

[ib18]

ok, I opened up my remote control and bypassed the neutral safety start switch by connecting the yellow red wires with a plier. I was able to send current to the starter but it barely spun the motor. I tried to spin the flywheel by hand, and it would not spin. Is something wrong with my flywheel? flywheel key is broken? hard to believe it just happened?

 

[ib18]

I fixed my battery cable connection today, still no luck. I jumped the 2 large solenoid posts to start the motor, but no luck. It looks like the solenoid and starter are both good. Unsure what would be the next step to troubleshoot this motor?

 

[Fed]

Check the Voltage between the battery posts at rest.
Check the Voltage between the battery posts while you are cranking it over.
Check the Voltage between the starter motor Positive post and the starter motor case while you are cranking it over.

You can hook up a temporary push button between the large Positive terminal (with the large single red wire) and the small Positive terminal (with the small single red/yellow wire) on the starter motor solenoid to help you if don't have a helper handy.

These 3 Voltage readings will tell you if you have a Voltage supply problem, a battery problem or a starter motor problem.

Your mention of not being able to turn the flywheel by hand is a worry, many people suggest not using starter fluid as it may not contain any lube. Right now if I was in your position I'd spray a little premix into the sparkplug holes and try turning it over by hand before doing anything else.

 

[ib18]

https://www.youtube.com/watch?v=XeC5jisD1SE

Thanks to Fed's suggestions. I will check them tomorrow. I found out after much research that I would not be able to spin the flywheel by hand if I don't have the spark plugs removed. There is no way my motor overheat, because I haven't started the motor successfully after I fix my stuck steering cable. My guess is I have a bad connections somewhere, so I am going to check all the terminals and connections. Test each connection with new wires to find the resistance in the starting system tomorrow. A pain in the butt to troubleshoot an electrical problem.

 

[ib18]

I think my starter solenoid is bad. I got only 1.2 volts (instead of 9.5 volts or above) between s-terminal (small terminal) and positive terminal from battery (large terminal) on solenoid when I turned my key switch to start the motor, Am I correct?

 

[Fed]

Check your Voltages to a good ground on the engine block.

 

[ib18]

Check your Voltages to a good ground on the engine block.

Fed, I have 8.6 volts between solenoid positive terminal to starting motor and motor housing (ground). I will check it between the solenoid positive terminal to starting motor and engine block later today.

I will also take down the solenoid, and bench test it to make sure 110% my solenoid is bad.