1969 Johnson 40 horse ignition problem

itstippy

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Jul 17, 2003
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548
Re: 1969 Johnson 40 horse ignition problem

The flywheel is already fudged and you have a replacement, so no harm that I can see in using a big ol' three-jaw puller to get it off.
 

skunkydan

Seaman Apprentice
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Jul 20, 2005
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34
Re: 1969 Johnson 40 horse ignition problem

About the replacement. It is off of model 40EL71G. Will this fit the same on the 69,as far as magnet length and spacing and shaft diameter and such.I dont want to officailly "fudge" the old flywheel unless I am sure the replacement will work, as I have it off, but the bad one is yet to be "removed"
 

Paul Moir

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Re: 1969 Johnson 40 horse ignition problem

There's something different about the electric start flywheel. I think it just might be how they're made (ring & flywheel together rather than separate) but just look and make sure it's got the same tooth spacing, etc. Internally it ought to be exactly the same.<br />The manual start flywheels '69 and '71 are the same.
 

skunkydan

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Re: 1969 Johnson 40 horse ignition problem

Ya that seems to be the only differance but the size/ diameter and teeth are the same, so I guess I will try it. The electric start is two pieces and the other is oe, but everything appears to be in the same place same measurements. So paul, you suggest just cutting , or grinding the flywheel off. Should I grind from the outside into the hub from a few sides and then just smack it apart. Should I go right up to the crank or stop 1/4 inch and try to crack it? The centre hub is much thicker than the rest. Here is what I have so far, the reason I am doing this.
dfhapz.jpg
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lark2004

Lieutenant Junior Grade
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Jul 12, 2004
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Re: 1969 Johnson 40 horse ignition problem

If you do try and cut it, make sure that you do it in line with flywheel key (so the cut ends up on the keyway) . You don't want to risk damaging the taper on the crankshaft.<br /><br />Also, be very carfull if you try to grind though the flywheel, alloy and grinders can be very dangerous, the alloy will clog up the pores of the cutoff/grinding wheel, and cause it to explode. I have seen this happen, trust me, you don't.
 

Paul Moir

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Re: 1969 Johnson 40 horse ignition problem

Yeesh, that flywheel is in a bad way!<br /><br />I've never had to do this before, but this is sort of what I imagined doing:<br />First, mask everything from the flywheel down. It should only take a few seconds and will really save the engine's life. Next, using a grinder cut the flywheel from the top in a circle just beyond the three puller bolt holes. Once through, remove most the flywheel and mask again. Then slit down the hub almost all the way to the crankshaft (perhaps with a saw so you don't have to remove ignition components to make room). That will releave the sttress on the hub. Then reattach the puller (using nuts if need be) and pull the reminants of the hub off. I suppose you could beat it off with a cold chisel at that point too, but the puller would be more delicate.<br /><br />But that's just a guess, since I've never had to do this.
 

skunkydan

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Jul 20, 2005
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Re: 1969 Johnson 40 horse ignition problem

Well, Thanks folks for all the help. I had an uncle come over today to "help". Thank goodness I had the spare flywheel.....now if only I could find a new crank...
dfxa12.jpg
This thread was getting a little long anyways. So I wont be using this motor next week :mad: One too many smacks on the crank as I was prying under the flywheel, "I've done it lots of times " he said. Well, now I can stop losing sleep over it. I do have another question, will the crank from a model 40EL71G engine work in this 69? It will be my winter project. So now I have to resort to a 1965 9.5 johnson and a 12 foot aluminum boat, I used the motor last year and it worked well, but this year,,, well,,,I started another link on that motor. I will and do have more questions about this motor, should I just keep using this thread? Notice also that the damb flywheel still didnt come off, just broke an inch off the end of the crank.
 

Paul Moir

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Re: 1969 Johnson 40 horse ignition problem

Gahh!<br />I have cleaned up mushroomed crankshaft threads before (before finding Iboats, and after finding a manual. :) ) but it's a real pain in the neck.<br /><br />EDIT: Oh, picture is coming through now. :eek: <br /><br />The crank is the same, it'll swap no problem. You'll need a 3/8" allen driver and a 12 point 5/16" socket for disassembly. The 12 point socket can be purchased from Sears. For reassembly you'll need an inch-lb reading torque wrench and a ft-lb. An impact screwdriver is a great asset.<br /><br />If your outboard had lived in salt in a previous life, you'll need a great deal of MAPP, patience, some really good drill bits, taps, and a collection of hammers. I've gone to "Permatex Motoseal #1 Grey" (Canadian Tire) for my crankcase halfs, but there's no reason why you can't use the proper stuff from the dealer. ;)
 

byacey

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Jul 20, 2005
Messages
443
Re: 1969 Johnson 40 horse ignition problem

skunkydan, <br />It's probably too late at this point to offer any advice, but to eliminate lots of problems I lock myself in the shop when I am working on something, and don't allow anyone else in to distract or "help"; not even the wife. Hope you get it going, sounds like you have had quite an ordeal...
 

skunkydan

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Re: 1969 Johnson 40 horse ignition problem

Thanks, as it stands,the boat is going to the back of the yard, and on tuesday, my wife and I are going on vacation, Northern Ontario, for 10 days, without the boat.hmm. I borrowed a 12 footer and a 9.5, that is running, umm, ok. when I get back I will begin rebuilding the powerhead, ALONE, IN THE SHOP< LOCKED. By then I should be thinking a little clearer, as of late I have been consumed by boat motors, but also way overstimulated by the human population and conversation in the stupid people catagory, I need the bush and the lake and the Loons
 

skunkydan

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Jul 20, 2005
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Re: 1969 Johnson 40 horse ignition problem

wow,did you know that it ONLY takes 30 minutes to go six miles in a 12 foot aluminum with a four horse Murc pushing on glass like water? Wonder what this 40 horse Johnny woulda done? What a trip. 2446 km on my old truck.
 

skunkydan

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Jul 20, 2005
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Re: 1969 Johnson 40 horse ignition problem

Also found out an IDIOT can make the same trip in 1 hour and 40 minutes in a high wind against 2 foot swells. The idiot also found that the 4 horse only holds a gallon of gas and doesnt go all 6 miles into the wind, full throttle in those conditions, only 5 miles.Anyone want to wager a guess how long it takes for 1 idiot, two oars, and a 12 foot aluminum boat to make the last mile in those conditions? I know the answer,and the idiot.lol<br />.
 

byacey

Chief Petty Officer
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Jul 20, 2005
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443
Re: 1969 Johnson 40 horse ignition problem

That sounds like the kind of situation where it is better to stay barricaded in your shop with a fine bottle of rum for company...
 
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