Johnson Warm-up Lever Problems

[Randyg123]

Re: Johnson Warm-up Lever Problems

As for the cable. If anything, you probably wanted to pull more of that center wire through if the cable is stretched.

Just tried that. Worse!
Then when I sat there and looked at it, it should have been obvious. Since I am pushing the cable to get the throttle to move the wire needs to be longer so I can get more action out of my warmup lever movement. The first portion of the warmup movement is just wasted on obtaining the tension between the casing anchor point and the control wire. If I could actually shorten the casing or move the anchor point on the cable and get another 1/4-3/8" of play, I think that would do it. But there is no way to do that. Maybe I am seeing it wrong and am missing something here. Any ideas?

 

[Randyg123]

Re: Johnson Warm-up Lever Problems

I had one of those Eureka moments last weekend as I was working on the other issues posted in other threads.

On the Controller, I noticed there was a bit of play on the cable when moving the warm-up lever (maybe about 3/16-1/4"). So I took off the controller cover and fashioned a shim (used the Dremel to cut up a bottle cap) to wedge the stop on the cable tighter into the receiver on the controller cover. I put the shim on the forward side of the cable stop and it now fit snuggly into the receiver.

Lo' and behold it worked! Although there was still some wiggle at the controller, enough was removed such that the warm-up lever would actually get the cam roller to line up with the START mark. Or at least close enough to where I won't complain one bit

Was there originally supposed to be some kind of sleeve that helped the cable stop fit in the cover tightly? Or perhaps the replacement cable just wasn't up to specs?

 

[Randyg123]

Re: Johnson Warm-up Lever Problems

I have looked at E/J's online parts catalog and saw that there is a part called a Trunion Cap (0319821). I cannot tell from the drawing if this is what I am looking for. Is this a sleeve that fits over the trunion so it mounts tighter in the control or does it go elsewhere?

 

[ezeke]

Re: Johnson Warm-up Lever Problems

The cover (casing guide) on the cable at the engine end has two set screws or two screws that can be loosened to make the initial adjustment to the cable length. Just follow the instructions in your service manual so you don't put too much pressure on the cable.

After you make the initial adjustment, you can use the trunnion nut to fit the lever perfectly. Edit: The trunnion nut is the wheel at the engine end.

 

[Randyg123]

Re: Johnson Warm-up Lever Problems

Thanks EZ but my problem is on the other end of the cable at the controller but unfortunately, there is no adjustment here. This end is fixed. Moving the warm-up lever up pushes the cable but it can only push so far. Wear on the controller parts may cause a little loss in this movement but as I mentioned above there appears to be too much movement where the trunnion mounts into the control box (Black round peg affixed to cable going into the round hole on controller). Johnson gives a part number for nylon trunnion caps and the OEM manual points to these (Figure 8-5). I just can't tell if these are separate parts that act as sleeves between the black plastic knob on the brass casing (as in 'caps' that cover these knobs) or if these ARE the black plastic knobs on the casing. Sorry if I am not clear on this issue. I may not be using the right terminology. I might have to take the controller apart and take some pictures. As they say a picture is worth a thousand words (and at least two thousand if using the wrong words).

So, if there are supposed to be some type of nylon cap over the trunnions on my shift and throttle cables, they aren't there and I need to find some.
P.S. both cables are rather new (1-2 years old).

 

[Randyg123]

Photos of Controller Trunnion

Photos of Controller Trunnion

Here are two photos that hopefully will help me explain what I am seeing.

The trunnion I am referring to is the black 'knob' attached to the brass casing in my hand. This goes directly into the round 'receiver' on the cover found in the other picture. There is no bushing or or sleeve in between these two. Should there be?

P.S. you can see the shim I fashioned resting on the brass casing on the far left of the trunnion photo. Right now, I wrap that around the black knob so it sits tightly and as far aft as possible in the cover. This gives me as much play as possible in the throttle cable so the warm-up leverl can push the wire as far back as possible.

 

[ezeke]

Re: Johnson Warm-up Lever Problems

The only throttle adjustment on the remote control is the throttle friction adjustment knob on the front side of the control box. The throttle cable adjustments have to be made at the engine. The only adjustable casing guide is at the engine and will have opposing set screws.

Some of the cables had a ball where you have a cylinder at the control clamp. Those cables required the cap but yours do not.

 

[Randyg123]

Re: Johnson Warm-up Lever Problems

.......Some of the cables had a ball where you have a cylinder at the control clamp. Those cables required the cap but yours do not.

Thanks, that answers my question. I wish I could just adjust the trunnion on that casing and move it fore about 3/16". That would allow me to take advantage of all of the warm-up levers movement, whereas now it is limited due to the extension of the casing into the lever's path. Maybe this is an issue with Teleflex manufacturing, I don't know.

Adding the shim help a lot. If anybody has a problem with their warm-up lever not moving the cam to the start position (after adjusting everything else per OEM manual), they should look at the cable where it enters the control box and see how much play there is there. Before, when I moved my lever up and down, you could see the cable casing moving in and out of the controller at least 1/4". After I put the shim there, I get less than an 1/8" movement. And this translates to more movement on the cam.

 

[ezeke]

Re: Johnson Warm-up Lever Problems

Not dealing with the cable, but with the travel of the warm-up lever, did you adjust the travel with the slotted screw at the top front side of the control box?

See page 8-2, figure 8-3 in the service manual.

 

[Randyg123]

Re: Johnson Warm-up Lever Problems

Not dealing with the cable, but with the travel of the warm-up lever, did you adjust the travel with the slotted screw at the top front side of the control box?

Yes,
That screw is wide open to give me all the play I can get. I probably mentioned some of this upstream in this thread but I also took the controller apart thinking I would find something obviously worn and thus limiting the action generated by the lever movement. Possibly a worn cam, gear, or pivot, etc. I didn't see anything obvious (but that doesn't mean there wasn't something).

I am assuming the cable shouldn't have that much 'wiggle' in it. That coupled with an old controller and possibly a bad or poorly manufactured cable, when all combined was giving me almost no movement translated at the cam. Now I have about 80-90% of what is needed with the controller maxed out. For now, that will do.