Johnson 130HP Starter Problem

[merheb]

I had drained dual batteries yesterday and had to get a jump to start a 1996 Johnson 130HP. Turns out that one of the batteries was apparently dead and drained the other one. This is on a boat I just recently purchased (2 month ago).<br /><br />Both batteries were bought in March this year and were EverStart Marine Max (875 MCA). I had them both replaced today with somewhat smaller batteries (EverStart Marine 675 MCA, dual-cycle). The engine manual says that the battery minimum is 465 MCA.<br /><br />After replacing the battery, the starter spins but it does not engage the flywheel. I saw a lot of posts here with a similar problem and did some troubleshooting: tightened battery connections and lubed the bendix gear shaft with no success. I just wanted to find out if they previous owner had "bigger" batteries because the starter needed it or was it just overkill? Is is a waste of cranking amps to go way overboard as the previous owner had?<br /><br />I plan on doing some more troubleshooting and just wanted to get some more info...<br /><br />Thanks,<br />Freddie

 

[Silvertip]

Re: Johnson 130HP Starter Problem

Turn the starter pinion gear counter clockwise by hand (engine off obviously) to make sure it rotates freely up the starter motor shaft. If it does, and you've checked all connections for clean and tight, you may have a starter that is in need of a rebuild or replacement. Bad brushes, shorted winding, tight bearings, etc., can make the starter turn hard and no matter how fresh the batteries are, it simply won't spin fast enough to run the pinion up to engage the flywheel. If you have dual batteries, are they on a battery switch? If not, add one. Simply paralleling the two batteries will always cause them to seek the charge level of the weaker of the two. This allows you to run on either battery individually or both simultaneously.

 

[merheb]

Re: Johnson 130HP Starter Problem

The pinion gear is actually free and I can move it up to engage the flywheel, just not on its own power.<br /><br />The weird thing about the electrical system is that there is a battery switch but the motor is tied in to one of the batteries directly. I cannot start it with the other battery.<br /><br />Unfortunately, there is a lot of work to be done regarding electrical wires on this boat but I was hoping that just a battery change would not make the starter work again...

 

[Walker]

Re: Johnson 130HP Starter Problem

Disconnect all battery cables and clean the cable clamps, battery terminals, battery cable end that bolts to the solenoid, cable end and area where it grounds to the engine block, and starter cable from solenoid to starter.

 

[Silvertip]

Re: Johnson 130HP Starter Problem

If doing everything Walker says still didn't solve the problem, connect jumper cables to a known good battery. Connect the negative cable to an unpainted bolt or other good ground on the engine block. Then (be prepared for a spark), touch the clamp on the positive cable directly to the cable post on the starter. If the starter now functions, you still have an electrical problem between the start battery and the starter. Continue testing by using a piece of short length of wire to jumper the solenoid from the point where the positive battery cable connects, to the small "start switch" terminal on the solenoid. If the starter still doesn't work the battery cables, terminal ends, or solenoid are bad. If the starter didn't work by directly jumping it with jumper cables, its not spinning up to speed and needs a rebuild, brushes, bearings, or armature (shorted).

 

[merheb]

Re: Johnson 130HP Starter Problem

Thanks a lot for the tips! I tried the jump cables and the starter worked. I cleaned all the battery connections and that took care of the problem!<br /><br />Now I ready for the next problem!