Starter for Johnson 35HP

[tlgustafson]

I have an old Johnson 35HP electric start motor that has worked great for the last 2.5 years until yesterday when the starter apparently failed. It only clicks when I turn the key, and the battery is fully charged (I tried two fully charged batteries just to make sure). I was able to start the motor by removing the cover and hand starting with a rope. It ran just fine.

Is there any other possible cause than the starter?

Is it possible that a starter repair kit may solve this rather than putting $$ into a new starter?

I found these three numbers stamped on the engine block:

326713
325744 . 1
324320

I've also attached three pics. Can anyone help me identify the year of the motor?

Thanks very much!

 

[ezeke]

Re: Starter for Johnson 35HP

Look on the port side of the transom bracket for a 1" X 3" plate with the model #. If that is not there, look on the engine block for a quarter-sized plug with a model number.

 

[Barnacle_Bill]

Re: Starter for Johnson 35HP

Check all your battery connections to be sure they are clean and tight. You can test the starter by using a heavy duty jumper from the + side of the battery direct to the + input of the starter. If the starter works, replace the starter solenoid.

 

[BoatBuoy]

Re: Starter for Johnson 35HP

Don't just check your connections. Remove them and clean them with a wire brush or sand paper - all them, from the battery through to the starter motor. Even those that look clean, may not be making connection.

 

[tlgustafson]

Re: Starter for Johnson 35HP

Thanks for the quick replies! I sanded the terminals and also jumped the positive battery terminal to the positive starter terminal. Neither helped. Still nothing but a click.

Any other ideas? I called a local marine shop and found that I have a 1981 motor. They have a refurbished starter in stock for $185 and they say it is a half hour labor to put it in for me ($60). Does that sound reasonable?

Thanks!

 

[Molaker]

Re: Starter for Johnson 35HP

First, try rotating your starter by hand (pliers or whatever). You may have a "dead" spot on the armature or just worn or dirty brushes.

Starters are pretty straightforward and can usually be rebuilt by most any automotive electrical shop. It's not difficult to take out a starter and re-install it. You may want to call around to automotive shops. If you find one that can do it, take the starter out yourself - just be sure to disconnect the battery before you go to work. I can't say how much, but I would expect you to be able to cut that $245 bill waaay down.

 

[tlgustafson]

Re: Starter for Johnson 35HP

Thanks for the advice. I'll check into that.

I've already tried rotating the starter several times. I was able to start the engine with a rope and it ran just fine. Everything so far seems to be pointing to the starter as the problem. Any other ideas?

Thanks for such great advice and so quickly at that!

 

[Molaker]

Re: Starter for Johnson 35HP

Only one last thought...I see that you jumped the starter directly to the battery positive post with no apparent difference. This only by-passed the positive cable. It is possible the negative cable has a problem. Try by-passing it (from battery negative post to engine block or starter housing) and hitting the start switch. Use a heavy cable like jumper cables.

 

[tlgustafson]

Re: Starter for Johnson 35HP

OK - I tried that and nothing changed. I did notice something else that I didn't notice before. When I make the connection on the positive cable (whether the negative is connected or not), the gear at the top of the starter spins. However, it's only periodic, not constant, and the gear doesn't raise so as to engage with the larger gear that turns the engine.

I hope this makes sense as I'm sure I'm not using the right terminology.

Thanks again for some great advice! Any other ideas?

I went on the web to wholesalemarine.com and found a starter that I think is the right one for $127.76, but I am a bit leary that I might order the wrong part. Any advice?

The description is: Outboard Starter for Johnson and Evinrude Engines. Fits 1985 - 1988 20hp, 1993 - 1998 20 thru 30hp and 1977 - 1988 25 thru 35hp. for Bosch models. Replaces O.E. 392133 585061 386591

And mine is a 1981 35HP. I don't know if it's Bosch or what the O.E. number is. I didn't see a number on the starter.

 

[Molaker]

Re: Starter for Johnson 35HP

Sounds like the starter for sure, very likely bad brushes. As for the p/n's, sorry, I can't help there.

 

[tlgustafson]

Re: Starter for Johnson 35HP

OK, thanks for the advice. It sounds like it's the starter. I've been looking around on the Internet and it looks like I can get a new starter for a little over $200 or an after-market starter for about $90. It's tempting to go with the least expensive option. Does anyone have advice regarding this?

I took a look at the starter and it's not obvious to me how to remove and replace it. I do have a friend, though, who could help. Unless of course one of you knows of instructions online somewhere?

Thanks again for some great support!

 

[Barnacle_Bill]

Re: Starter for Johnson 35HP

Most auto electric shops can rebuild that starter for you.

 

[tlgustafson]

Re: Starter for Johnson 35HP

Where would I get a manual?

Thanks

 

[Barnacle_Bill]

Re: Starter for Johnson 35HP

http://www.iboats.com/Johnson_Evinrude_Outboard_Repair_Manuals/dm/category_id.251023--view_id.251023

 

[tlgustafson]

Re: Starter for Johnson 35HP

OK - looks good. How does a person decide if the starter should be replaced or rebuilt?

 

[darrklim2]

Re: Starter for Johnson 35HP

99% of the time the starter can be rebuilt. Unless there is physical damage to it or serious water damage(causing pitting to the case or shaft etc. The repair shop will be able to tell if it is rebuildable when they open it up.

 

[tlgustafson]

Re: Starter for Johnson 35HP

OK - one last question. I found a shop in the area that will rebuild the starter for me and their rate is $40/hour. I just need to get the starter off the motor and bring it in.

Can anyone give me some hints about how to remove the starter (recall it's a 1981 Johnson outboard 35HP). I've given it a look and it's not obvious. Do I have to remove the entire metal casing with the solenoid and starter motor, or is there a way to get the starter motor out by itself?

I'm no mechanical genius, but I can get around if someone points me in the right direction.

Thanks - you guys are awesome!

 

[jwaldrop]

Re: Starter for Johnson 35HP

Disconnect battery FIRST. Two bolts on top of starter housing, one nut near carb. and two screws at rear of housing on top, disconnect the cable and it's out.

 

[Kettler]

Re: Starter for Johnson 35HP

I was taught in aircraft maintenance school never to use sand paper or an emery board in battery terminals.Use a Wire Brush or scotchbrite.