Tagged’s 140 Johnson Resurrection

[Tagged]

Tonight, I really did do a couple of honey-do’s and I really did clean my workbench. I needed to, because I dug into the wiring harness.

My motor didnt come come with the tilt/trim relay box. And my donor didn’t have one either, because the relays are all mounted to the motor, next to the brain boxes. So I disassembled the donor wiring harness to isolate the TT relay circuit.

I have the the wiring diagrams for both motors, and the donor relay circuit has all the right pieces, I think. It’ll take a few more evenings to sort it out, but I’ll get there. Once I get the motor resurrected, I’ll create a permanent relay box in the boat, and a custom wiring harness.

For tonight, only a picture of the donor octopus. It doesn’t look like much, but it’s a big deal.

 

[spybot]

Hey Tag that looks better than mine. Unfortunately i have to do a complete rewire on mine. The bit that annoys me most is waiting on the wire connectors coming from the US plus paying more on postage and tax than i pay for the terminals :blue:

 

[racerone]

Does your 82 model; have a 3 wire trim motor ?-----Does the 96 have a 2 wire motor ?

 

[Tagged]

Does your 82 model; have a 3 wire trim motor ?-----Does the 96 have a 2 wire motor ?

I got lucky. They’re both two-wire motors. The wiring diagram for the 96 has a couple of extras that I won’t need on the 82. There’s a second set of controls on the side of the cowl that I can eliminate.

Spybot, to save money on my custom wiring harness, I’m probably going to convert most of the proprietary BRP connecors to simple ring terminals and bullet connectors.

 

[spybot]

Thats a good shout Tag never thought of that.Fully insulated bullets i will be using them instead. i dont intend selling this motor, I have a lot of hours and cash invested in her.
Sometimes i dont see the forest for all the trees in front of me :facepalm:
Andy

 

[Tagged]

My battery is crap. Mostly dead. Won’t fire the coils more than once or twice. So tonight I decided to jump-start it off my son’s car, to check spark. Just to settle that nervous voice that telling me the stator might be bad.

So so we hooked up some jumper cables, and it wouldn’t turn over. Solenoid didn’t even click. Nothing.

Mind you, five minutes earlier, I was turning over on the battery, and everything was fine. With jumper cables? Nothing.

Now, here’s where it gets weird. I scratched my head and took a break. Figured I had popped the fuse or something. Came back five minutes later, no jumper cables, and it turned over just fine.

What gives? Any ideas?

 

[Tagged]

Happy happy! Thank you, Ken Cook, and may you Rest In Peace.

 

[Tagged]

Well, darn it. I broke one off. Now what?

water jacket bolt right above the #3 spark plug.

Dang it.

 

[spybot]

My battery is crap. Mostly dead. Won’t fire the coils more than once or twice. So tonight I decided to jump-start it off my son’s car, to check spark. Just to settle that nervous voice that telling me the stator might be bad.

So so we hooked up some jumper cables, and it wouldn’t turn over. Solenoid didn’t even click. Nothing.

Mind you, five minutes earlier, I was turning over on the battery, and everything was fine. With jumper cables? Nothing.

Now, here’s where it gets weird. I scratched my head and took a break. Figured I had popped the fuse or something. Came back five minutes later, no jumper cables, and it turned over just fine.

What gives? Any ideas?

May be you knocked the throttle on the control panel and it may have moved so the ingear switch would not let you start it???

Other times it wont start are if the kill switch is activated or shorted out. this only kills the coils
If the ignition switch is faulty/ in the off position kills the coils
Have you tried to jump it straight from the starter its self ?
I have limited knowledge on this side of things only going on what i have learned through experience
Andy

 

[spybot]

Well, darn it. I broke one off. Now what?

water jacket bolt right above the #3 spark plug.

Dang it.

Post a pic and i will be able to talk you though the extraction
Andy

 

[Tagged]

The end of the stud is barely less than flush with the top of the cover plate. That is, it broke right at the head of the bolt.

It looks like it’s rusted and swollen at the cover plate. All the the other bolts are out, and the plate can not be removed because this one broken bolt is still holding it on.

 

[oldrem]

Looks like a lot of rust is all that's holding it. I would start with a lot of penetrating oil for a couple days. Might loosen up enough that you could get the cover off. Should be a lot easier to get the bolt out with the cover off, otherwise you're looking at using an easy-out

 

[Tagged]

Maybe I should rename this thread “the Broken Bolt Restoration Project.” Y’all already know how nervous I am about broken bolts like this.

I also have have two lower unit bolts that the previous owner broke off. Makes me nervous about the impeller job I’m going to need to do.

 

[racerone]

Don't fool yourself.---A 1982 model 140 crossflow should be torn down for complete inspection before spending any money on parts.----They have a history and it is now 35 years old.

 

[Tagged]

History? I thought these motors had a good reputation. Is that wrong?

Tonight’s progress: new battery and confirmed spark to all cylinders. Removed starboard water jacket cover (but not the one broken bolt). Cleaned the passages between the cover and gasket, just like the port side.

Removed and and cleaned the top carb. It was remarkably clean. It even still had liquid fuel in it. Thick, stinky, fuel, but liquid is better than varnish.

All told, tonight was a good night. I didn’t even break anything. ;-)

Tag

 

[jimmbo]

As pointed out it is 35 yrs old, and looking at the cylinder head with the water jacket cover off, and the fitting for the hose to the thermostat housing it show a lot crud in the cooling passages. May have been a salt water engine or some brackish water.
As for the good reputation, they are solidly engineered engines, but longevity depends on many things

 

[Tagged]

That makes sense. The crud in the cooling passages isn’t the worst I’ve seen, but you’re right, it’s not the best either.

 

[racerone]

Some will argue.----These motors have a history of breaking the piston rings !

 

[Tagged]

Gotcha. What’s the symptoms of broken rings? Loss of compression in the dead cylinder, I’d imagine. What else should I watch for?

 

[spybot]

As soon as you get a stuck ring burst ring you will know about. Remove the head and you will see something like these