Johnson Warm-up Lever Problems

[Randyg123]

1975 135HP Johnson
Following the manual my warm-up lever should be able to rotate the throttle cam to the START position. But it doesn't. Barely makes it half way even with the limit screw on the controller all the way out. Assuming everything else is okay, with the linkage and cable is there any other adjustment that can be made to get more action out of the lever. It seems like there is just too much play in it since the first 50% of travel doesn't really get translated on the engine.

Looking at the different diagrams in the manual of this controller I am having a hard time determining exactly how the warm-up lever is functioning but I am assuming something is worn down or loose. Taking apart the Controller looks as though I may be opening up a can of worms so I am not sure I want to take it apart just to get a "Look-See". But knowing me, I will anyways; so please stop me if this is a bad idea

 

[tashasdaddy]

Re: Johnson Warm-up Lever Problems

very possible you cable has stretched. how old is it. how far do you have to move the main handle to get throttle. they work the same cable.

 

[iwombat]

Re: Johnson Warm-up Lever Problems

I can't imagine what would be worn in the control that's specific only to the warm-up lever. I think you've got a cable adjustment issue.

How are you setting up your throttle cable?

 

[ezeke]

Re: Johnson Warm-up Lever Problems

You must first have both the shift cable and throttle cable set correctly at the engine.

The warm up lever can only be raised/used when the control arm is in neutral position.

The adjustment screw for the warm-up lever is at the front of the remote control.

When the warm up lever is raised all the way up to the start position, the mark on the word "start" at the engine should point directly to the center of the throttle cam roller.

If the engine is too slow, turn the adjustment screw on the front of the remote clockwise to increase.

 

[F_R]

Re: Johnson Warm-up Lever Problems

Probably the black plastic adjusting nut at the engine end of the cable is out of adjustment.

 

[Randyg123]

Re: Johnson Warm-up Lever Problems

very possible you cable has stretched. how old is it. how far do you have to move the main handle to get throttle. they work the same cable.

New cable put in a few years back. I am going to take some photos of the controller postitions and will post those soon.

 

[Randyg123]

Re: Johnson Warm-up Lever Problems

These are photos of my controller and linkage when 1) the Controller is in Neutral with the Warmup Lever down and 2) controller advanced until throttle arm starts to move.

More photos in my next post

 

[Randyg123]

Re: Johnson Warm-up Lever Problems

These are photos of the Controller and Linkage 3) the moment the Camfollower roller lines up with the top notch and 4) at WOT

final photos of Warmup lever up in next post

 

[Randyg123]

Re: Johnson Warm-up Lever Problems

Finally, these are photos of the Controller and Linkage when the controller is in neutral with Warmup Lever Full up.

I hope these series of photos can help you diagnose my throttle cable linkage and if there are any issues that stick out.

Many thanks in advance

 

[iwombat]

Re: Johnson Warm-up Lever Problems

That's sure a lot of throttle to get to the "start" position.

Place your control in the neutral & idle position (center).

Then,

At the motor end remove the throttle cable from the throttle lever.
By hand, move the throttle lever to the idle position.
With the throttle cable still disconnected, but held in the carrier adjust the trunion to match the connector event to the position of the throttle lever.
Now, reconnect the cable.

You should remove most (but not all) of the slack in the cable.

The fast start lever should now be a little more effective.

 

[Randyg123]

Re: Johnson Warm-up Lever Problems

...
At the motor end remove the throttle cable from the throttle lever.
By hand, move the throttle lever to the idle position....

By this do you mean push the throttle lever back to make sure the idle stop is making contact?

 

[greg n]

Re: Johnson Warm-up Lever Problems

I don't know if you have already tore into it but go ahead, i have mine and there isn't anything complicated about it. Any questions just ask, i have the same exact i'll bet. Also, what brand tilt & trim does yours have? I have a prestolite and it leaks down somewhat and I can't seem to find parts. Any ideas from everyone would be appreciated. It's on a 75, 135 evinrude.

 

[Randyg123]

Re: Johnson Warm-up Lever Problems

I don't know if you have already tore into it but go ahead, i have mine and there isn't anything complicated about it. Any questions just ask, i have the same exact i'll bet. Also, what brand tilt & trim does yours have? I have a prestolite and it leaks down somewhat and I can't seem to find parts. Any ideas from everyone would be appreciated. It's on a 75, 135 evinrude.

Thanks for the offer. I may take you up on the assist if I have to take it apart. Hopefully the cable adjustment will suffice

As for the TnT I think mine is the Prestolite but it looks like it's been, how should I say, "after-market refurbished by a very thrifty mechanic" The motor bracket on my 135HP is actually from a 1973 85HP (in fact until a few days ago I thought my motor WAS an 85HP!!). My TnT pump is hanging on by a thread and I am afraid to even touch it. I've got to settle all the other problems first

 

[iwombat]

Re: Johnson Warm-up Lever Problems

By this do you mean push the throttle lever back to make sure the idle stop is making contact?

That's exactly what I mean.

 

[Randyg123]

Re: Johnson Warm-up Lever Problems

That's sure a lot of throttle to get to the "start" position.

Place your control in the neutral & idle position (center).

Then,

At the motor end remove the throttle cable from the throttle lever.
By hand, move the throttle lever to the idle position.
With the throttle cable still disconnected, but held in the carrier adjust the trunion to match the connector event to the position of the throttle lever.
Now, reconnect the cable.

You should remove most (but not all) of the slack in the cable.

The fast start lever should now be a little more effective.

Well I tried it. When I loosened the clip on the cable, and the throttle was at idle, the cable end slipped right off as there was zero tension. Checked everything again but the cable seemed to be adjusted quite well. I started to look at the cable and its connector for any clues but got chased in the house by the tornado sirens

What I did see before running inside was that the black part was allowing the brass rod to move quite a bit back and forth. Is this okay? I'll get a better look later, assuming the boat is still there.

 

[Randyg123]

Re: Johnson Warm-up Lever Problems

What I may try to do is go back to square one and re-install the throttle cable. But, can this be done? I am worried the the control wire already being kinked will not be adjustable, will break, or will keep resetting to its original place when tightening the clamp screw.

Does anybody have any experience in re-adjusting these cables?

 

[Randyg123]

Re: Johnson Warm-up Lever Problems

Okay,
I pulled the cover off the controller and checked the cable attachment to see if there were any anomalies. What I found was that the control wire extended past the casing guide about 1/4-5/16". So I loosened up the clamp screws and re-installed with the control wire end flush with the casing guide.

Then, on the throttle end of the cable, I checked alignment and all was okay. Overall this adjustment may have gained me some extra movement on the cam but it really wasn't too significant.

Too make matter worse, after messing around with the controller, I lost my spark. The engine would crank but no spark. At first I thought I may have jostled the 'kill switch' wire when working in a very tight location to get my controller off the boat side. But this seemed to be okay. With the front cover off the controller, I just reached up into the wiring harness and did some tugging and squeezing and voila, I got my spark back. So then I took the controller apart to get better access to the wires but could find nothing obviously loose or broken.

It's working right now but there is obviously something wrong in there. Does anybody have an idea which circuit may be the culprit (which one would kill the ignition system) in the control box?

 

[iwombat]

Re: Johnson Warm-up Lever Problems

The real name is escaping me at the moment but the doohickey that tells if you're in neutral is probably the one causing you grief.

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

 

[Randyg123]

Re: Johnson Warm-up Lever Problems

The real name is escaping me at the moment but the doohickey that tells if you're in neutral is probably the one causing you grief.

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

I think you are referring to the "start-in-neutral only" switch but doohickey is much more on my level I thought of that but then figured that this switch would prevent the starter from turning as well as cutting the power to the ignition system. So does this switch not cut-off the starting system as well? Wait bad question grammar. Does this switch control the starting system, the ignition system, or both?

 

[iwombat]

Re: Johnson Warm-up Lever Problems

Hrm . . . I believe that it cuts the power to the starter solenoid. So yeah, you're right. In that case, look at the back of the ignition switch to make sure all the screws are in tight and the connectors are clean.