johnson 120 constant warning whistle

[z86roc28]

My 1992 johnson 120 has a constant warning whistle blowing. This was happening to me on and off at the end of last season. I just brought it out of storage today, started it up, and the whistle is blowing--but here is the thing that I dont get--the whistle blows constantly before the engine starts--that is, with the key in the RUN position.

The constant whistle I guess is one of two things--A)over heat--which doesnt make sense because the whistle started before the engine was started or B) fuel restiction--which puzzles me because the engine runs well.

I figure it is a fuel problem or a problem with the warning system itself.
Questions:
If the system were to signal a fuel restriction, wouldn't the whistle start only after the engine started?
What would malfunction in the warning system to cause the whistle to blow constantly no matter what?
What type of fuel restriction would alert the system before the engine started?.

Any help would be greatly appreciated as you can see I really dont know where to start.

The engine is on a 1993 four winns 180 freedom

 

[tashasdaddy]

Re: johnson 120 constant warning whistle

is the vro active?

 

[z86roc28]

Re: johnson 120 constant warning whistle

yes the vro is active

 

[Joe Reeves]

Re: johnson 120 constant warning whistle

Remove the TAN wire from the warning horn while the horn is beeping. If the beeping continues with that TAN wire disconnected, replace the horn.

 

[z86roc28]

Re: johnson 120 constant warning whistle

ok, so i get back in the boat, i turn the key to the run position, and it works as normal--gives the one second whistle to let you know it works. I try it again, and back to square one, there is something loose or failing intermittently somewhere, i just dont really know where to start looking!!

I tried removing the tan wire from the whistle---it shuts off immediately---by the way, thanks for letting me know how to shut the damn thing off LOL!! Where to now?

 

[z86roc28]

Re: johnson 120 constant warning whistle

how does the system detect a fuel restriction?

 

[Joe Reeves]

Re: johnson 120 constant warning whistle

To my knowledge, there is no fuel restriction warning on the 1992 120/140 hp models.

I'd suggest...... With the horn sounding constantly such as you describe, start disconnecting the related components at the engine, one by one, until the horn ceases to beep. That should reveal the affected component.

Components...... Oil tank level electrical connection, VRO electrical connector plug, port and starboard overheat sensors. If I've missed anything, someone jump in here with the correction.

 

[z86roc28]

Re: johnson 120 constant warning whistle

I unhooked the two overheat sensors earlier, didnt help, I will look for the other items you listed.

 

[z86roc28]

Re: johnson 120 constant warning whistle

By the way, where are these two things? Oil tank level electrical connection, VRO electrical connector plug

 

[Joe Reeves]

Re: johnson 120 constant warning whistle

I neglected to mention the Fuel Restriction Vacuum Switch also.

VRO... Large black plastic component with fuel lines running to it. Look at the smaller end of it. Follow wires to the rubber connector plug and unplug it.

Vacuum switch... Usually a grayish plastic looking item with a smaller diameter fuel hose attached to it. Normally somewhere near the VRO pump on the port side of the engine.

Oil tank wires... Looks like lamp cord wire. One wire will be attached to a ground. The other is usually attached to a TAN wire via a knife disconnect type connection.

 

[z86roc28]

Re: johnson 120 constant warning whistle

Thanks, I am going to have to try it later on this week---I will let you know what happened----THANKS

 

[z86roc28]

Re: johnson 120 constant warning whistle

I unhook the oiltank wires and the whistle instantly stops. What needs to be replaced? Thanks for the help!

 

[ezeke]

Re: johnson 120 constant warning whistle

Probably the blocking diode in the harness and possibly the ignition switch.

 

[z86roc28]

Re: johnson 120 constant warning whistle

can I run the engine with the level sensor unplugged? as long as I check the oil level every time I operate the engine? now that I have narrowed the problem how do I solve/diagnose it?

 

[plasmacon]

Re: johnson 120 constant warning whistle

I have the same problem. The horn is functioning properly, and I have traced the wiring down to the oil tank line. The motor runs great and smokes on the trailer. I don't understand what I should replace. Is the oil pickup bad or just a sensor. I think it is getting oil, but not sure if it is getting too much. When I disconnect the tan wire going to the oil tank, the horn shuts off, this is only with the key on. The motor doesn't have to be running. Just wondering what I should replace? Can I just disconnect until parts arrive?

1984 Johnson 235HP. Not sure if original or updated in any way.

Thanks for any help.