Johnson 1989 40HP starting problem

JoeW80

Cadet
Joined
May 16, 2009
Messages
21
Hi everyone,

This is my first boat and I am having intermittent problems starting up. Once started, it runs fine and it will start back up easily after being turned off for a short period of time.

Here's my starting procedure:
1) prime the bulb until stiff
2) ensure in neutral
3) lift high idle lever up all the way
4) turn key and push in after about a second

When the key is turned, I hear the starter cranking. I removed the motor cover and observed it engaging and turning. However, the motor does not seem to fire or sometimes it will fire for a second, a little bit of smoke comes out, and it will stall. I continue doing this and it seems to start eventually... sometimes it takes 5-10 minutes of cranking and then almost miraculously starts. I haven't been able to notice a difference between the cranking when it starts and when it doesn't start.

I noticed that the starter and flywheel has worn/chipped teeth, but like I said it does engage and turn. The battery is fully charged and I observe the voltage dropping from 12.5V to 11.7V on the fishfinder. I would like to check the voltage drop from the battery to the starter solenoid, but I haven't taken the multimeter with me out on the water.

I don't have much experience with boats and motors.. I just ordered a manual. I had a mechanic check it out and he says everything looks fine, he was able to start it in one try and suggests that maybe it's my technique. He installed a fuel filter/water seperator because he found water in the motor. He also checked the compression and told me there were no leaks in the fuel lines. The previous owner says he recently replaced the spark plugs and wires and they appear to be in good condition.. I didn't pull them but I'm assuming the mechanic did when he checked it out.

I know this is long and I appreciate your time reading. I would greatly appreciate any suggestions to troubleshoot this further. If anyone has had similar problems, please share the details on how you resolved it. Thank you!
 

Lelabach

Recruit
Joined
Jul 1, 2010
Messages
1
Re: Johnson 1989 40HP starting problem

hello there i was wondering what you ended up doing with this situation since i am having the same problem with a 40HP Force Mercury and am wondering if i need to purchase a starter rebuild kit since i am thinking it is the starter itself. ;)
 

JoeW80

Cadet
Joined
May 16, 2009
Messages
21
Re: Johnson 1989 40HP starting problem

Hi Lelabach,

I took it to a mechanic after this post and he looked it over. He installed a fuel filter / water seperator. I don't believe this was the whole problem, but it may have contributed.

I also found an extremely helpful post on here that goes through the starting procedures for the engine. The link is http://forums.iboats.com/showthread.php?t=225510. This is for the Johnson / Evinrude engines so I'm not sure if it will help you. My problem was using the fuel enricher properly, which is what pushing in the key does for my engine (on some engines this activates a choke).

As far as the starter, I would first take the engine cover off and visually make sure that the starter is cranking when you turn the key. Next, there are some voltage measurements that you should make. You want to be sure that there isn't a large voltage drop between your battery and the starter, since the wiring could have poor conductivity or contact due to corrosion or just being loose. I would recommend googling "Boat starter troubleshooting" or something similar. I have a troubleshooting guide for many engines, including yours. I could email it to you if you'd like, but it's too big to post in this forum.
 

Prophammer

Chief Petty Officer
Joined
Jul 2, 2010
Messages
473
Re: Johnson 1989 40HP starting problem

Could be you're not choking it enough and/or giving it too much throttle, those are the only things I can think of, especially if it runs ok otherwise.
 
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