1991 Johnson 48SPL... I broke a part because I'm a moron! :(

[OldPete]

Johnson 0432015

Any help appreciated. I have it glued now... but I'm not certain I trust it.

 

[Silvertip]

It might help if we knew what part it was you broke? What glue did you use?

 

[racerone]

Should be easy to find that lever used I think.----Your location ?

 

[OldPete]

I'm in South Florida.

 

[OldPete]

Part number is listed in this thread.


Glue used: Loctite SuperGlue UltraGelControl

I was thinking of doing some biaxial in thin strips with epoxy as well...?

 

[racerone]

Some single strands of fiberglass / JB weld epoxy work well for these types of repairs.-----Depends on where it broke of course.----Time consuming but you have to do that if no other way.----I do believe that part should be easy to find in many places !

 

[OldPete]

While I'm at it... Any ideas why this is like this

 

[tphoyt]

Sure sounds like an air gap issue to me

 

[OldPete]

Well crap... the mods removed the link to the rest of my problem. That sort of rendered the rest of the thread useless...

I'll post up the same info directly here.

Had to change the ignition module on the motor.
Not terrible job... until I put back together and test.

First I busted the timing linkage bracket. I managed to cobble it together (sort of). I’m looking for a new one.

It appears it broke because something is not right with the linkage. The throttle (at control) is very hard to move and when you manage to move it, the flywheel rotates.... which I do not recall seeing before.

I’m going to post up some video and pictures with the hope of someone seeing a “you dummy” moment.

If any other pics or video is needed... let me know.

I can tell you that it will not start. Appears to be timing.
#2 cylinder (bottom cylinder) when all the way up (up toward spark plug hole) is 180 on flywheel from when the #1 cylinder is same.

Does anyone know if that timing plate under the flywheel should rotate that much?? To the point where the arm on the timing bracket is the only thing that stabilized it?

Lastly I know the Frankenpart repair on that bracket is an issue.

(Hopefully a YouTube video of my issue is allowed.)

 

[OldPete]

[No message]

 

[racerone]

Pull the flywheel.----Fix what is rubbing on the flywheel.----Simple procedure.

 

[tphoyt]

I'm in agreement on this
Do you understand what we mean by the air gap?
You really need to pull that fly wheel. your linkage shouldn't move with the flywheel.
There is likely a problem with the coil under the flywheel a screw broke or came lose and the magnet is catching and dragging your timing plate with it.

 

[OldPete]

I have now pulled the flywheel 3 times. There is exactly nothing rubbing on the fly wheel.


I have gone over the diagrams in the service manual (OMC) and the exploded parts diagram and there are no "broken screws" or anything like that. The stator, the coil, and the ignition module are all free from damage and not rubbing at all.

The coil is on with the correct screws (a 15 (left side) and a 56 (right side where the module goes over it)) (see diagram:
https://www.boats.net/catalog/johnson/outboard-by-hp/48hp/j48esleim-1991/ignition-system )


After Dorian passes, I will remove it for the 4th time. However the air gap is the same as it was prior to taking it apart.

Furthermore, could someone please explain how even if the air gap was off... how, exactly, would that cause the bottom plate to move like it does. My understanding is that the air gap is set to ensure proper distance between the coil, etc. from the inside of the flywheel. That isn't going to do anything at all to prevent that lower ignition plate from moving.

Thanks for all the help here! I look forward to solving this with your help. Pete

 

[Tim Frank]

Part number is listed in this thread.

Glue used: Loctite SuperGlue UltraGelControl

I was thinking of doing some biaxial in thin strips with epoxy as well...?

I think what Silvertip may have meant was that including the part name and description would mean that you are not expecting people to try and look up a part number when a few secionds typing by you would help us all out....since you already know what the part is.


Agree with Racerone....used part would be the way to go.

 

[OldPete]

I think what Silvertip may have meant was that including the part name and description would mean that you are not expecting people to try and look up a part number when a few secionds typing by you would help us all out....since you already know what the part is.


Agree with Racerone....used part would be the way to go.

Ah. Thanks for clearing that up. Now that the thread has matured to include pictures, etc... I think we can move beyond that.

P.S. If I posted the part, without the number -- I'll bet we would have posted a link to the diagram with the part number... but that's for your help.

 

[juno pierrat]

if air gap good, in the parts breakdown on Iboats for this motor, something binding in armature plate assembly parts 1, 61, 6, 57, or something to high hitting under side of flywheel