Johnson 88hp intermittent starting problem

[windshear]

Looking for ideas to pinpoint a starting problem.
1988 Johnson 88HP V4 outboard, Model#J88MSLCCC. The control box is OMC, I think it's older than the engine. I turn the key and sometimes nothing at all happens, not a sound. The solenoid and starter seem to be fine and it has a new battery. I'll move things around (warmup lever, try the key several times, move the shifter) and suddenly either the engine just starts or I hear a light sound from the control box and I know it's going to going to start any second. So..bad ignition switch? Faulty cut-out switch in the control box? I have not opened the control box yet. Any ideas?

 

[ob]

Re: Johnson 88hp intermittent starting problem

I think you're on the right track on the control box.Sounds like a neutral safety switch issue.

 

[windshear]

Re: Johnson 88hp intermittent starting problem

I replaced the control box with a rebuilt one and still the same exact problem. It will not start with the key. It only starts if I touch a wire to the solenoid and the positive battery post. The engine then runs great. The troubleshooting that I read now pretty much leaves just wiring at the engine as the problem. But i'm not sure which wire is the most likely culprit. any thoughts?

 

[HighTrim]

Re: Johnson 88hp intermittent starting problem

Make sure all connections are shiny and clean, no corrosion, rust, dirt, etc... Wires rot from the inside out and are usually hard to detect, check for kinks, corrosion, cuts, splices. Replacing the wiring is fairly cheap if it looks old. Check for arcing, may be easier to see at night.

 

[windshear]

Re: Johnson 88hp intermittent starting problem

Thanks HighTrim. The problem was in the wiring. The engine side of the main wiring harness had a corroded starter pin. Found it by tugging on the pins and this one broke off with ease showing the corrosion. One of those hidden problems.... Now it starts fine and the primer works fine too.