1969 Johnson 115 quit firing

[Bob37814]

I noticed there was a second plug that comes off the pulse pack that looks like it runs to some sort of location under the flywheel. These wires were badly corroded and the insulation is brittle. With the plugs out and grounded, I can wiggle these 2 wires and the spark plugs will start popping with a big visable blue spark. But, when I crank it, I have no spark...Any takers?

 

[tashasdaddy]

Re: 1969 Johnson 115 quit firing

you need a OEM service manual. also a new wiring harness. any short can blow those power packs. we had a 69 115, had to replace powerpacks every 2-3 years.

 

[F_R]

Re: 1969 Johnson 115 quit firing

Those wires go to the sensor that tells the pulse pack when to fire. That is a complicated and sensitive system. Easy to cost you big $$$ from just one little mistake or bad connection. Get a factory service manual and heed it.

I assume from your description that somebody has already disconnected the safety circuit. Be careful, that thing can start up by just turning the key on. That is what the safety circuit prevents. It can also run backwards. That is what the anti-reverse cut-out ring is for.

 

[Bob37814]

Re: 1969 Johnson 115 quit firing

I have the OEM Johnson manual for this motor. Yes, it looks to have clipped wireson the ignition safety circuit assembly. Now, When I plug and unplug the double wire plug that runs out from the sensor under the flywheel, I hear a small audible click or light tick if you will, coming from the pulse pack. I am assuming this is the pulse pack switching off and on? Also, other than these 2 wires (which are badly frayed and corroded with insulation falling off) The rest of the wiring harness appears in good condition to me. Can these 2 wires be replaced or am I going to have to find a new sensor???? This unit ran great 2 days ago just before I replaced the starter with a new one. The pulse pack looks very close to new. This is a great old eggbeater, compression is all in the high 120's, and had a super hot 1/2 inch blue spark straight off the head. this things' safety setup seems to look like it has been completely disabled. I can see how this thing could start right up on someone with the key in the on position. I thought this through myself and took warning. By chance, would any of you know what size socket it takes for the flywheel nut????

 

[F_R]

Re: 1969 Johnson 115 quit firing

The cable between the pulse pack plug and sensor is part number 510786 and is available from your dealer or direct from BRP for only $3.46---cheap, considering the price of everything else. I could tell you the size of the nut by going out to my shop and looking at my socket, but it is easier for you to just stick a ruler across the flats and measure it. Maybe 1 3/8"????

BRP's parts website is http://shop.evinrude.com/

 

[Bob37814]

Re: 1969 Johnson 115 quit firing

Wow FR, That sounds good....real good. I should have known to look into getting those nasty bare wires corrected before I even turned over that motor. I just sank some big bucks into a brand new starter to replace the factory prestolite unit that had a shorted armature. What do you think the chances are that I zapped my pulse pack???? 10 minutes ago, I had a friend of mine turn the key on and off and I can still hear a faint mellow click in the pack its self. it sounds like its getting juice

 

[F_R]

Re: 1969 Johnson 115 quit firing

You have spark....the pulse pack is working.

 

[Bob37814]

Re: 1969 Johnson 115 quit firing

Good deal. Depending on what this crazy weather acts like down here in East TN, I may get to work on getting her apart today and getting it prepared for that harness you mentioned. Too cold and I'll wait til the first of next week. I am like you, I believe that pulse pack is still good, yet i'm gonna wait til I get this harness and get it installed before I go to cranking any more on it. I'll post results as I recieve them. Thanks a lot you have been helpful

 

[Bob37814]

Re: 1969 Johnson 115 quit firing

Ok just an update....Got a socket to remove flywheel, disassembled it down to the sensor plate and replaced the bad wires with good ones bought at a local marina. Pack is NOT fried thank goodness WHEW!!!!! Got my hot blue 1/2 inch spark back and it starts again. Now after I chase down me a new top carburator return spring, I should have a good motor....So far, all I have done to the motor at this point is tore down and rebuilt the carbs, the new sensor harness, and a new starter.....I was told it hadnt run in 2 years but I cleaned and rebuilt carbs anyway. I ran it in a big plastic tote full of water and it never got hot, Still not gonna chance all that. I got a new water pump kit and a couple quarts of type c lube and thats all next on the list before season starts. Basically, all I need now is time.....Thanks to FR for all your help. See you on the water - Safe Boating