johnson controls...or lack therof

[glust]

Fellow boaters.. I have a 1982 johnson 140 crossflow with what appears like matching controls. I have it out of a 1992 sun tracker 30' pontoon boat with the swim platform. Motor runs fine but when I send the throttle handle fully extended forward I am only getting maybe 1/2 open of the butterfly. When returning the throttle back to neutral the cable does not pull the linkage back far enough to retune the motor to idle. The linkage seems to be rocking around on the pivot some leaving me to think i need to replace the plastic bushing on the pivot. I have a manual and have followed and understand the procedure for a link and sync. My issue is if I adjust the wheel on the cable to get the butterflies open horizontal, I can't get the cam back to idle when I plush throttle back. The cable seems tight . Should I lube it in the same way you lube a motorcycle cable. Replace the cable? Any help would be appreciated. I have the motor, cables, controls and wiring on a test stand in the garage. Wanted to get this taken care of in the off season. The way it is now the boat will only do about 15 mph. I realize what I have and I am not looking to burn up the lake, its a big heavy boat. But I would like to have WOT when I want it. Thanks everyone.

 

[jbcurt00]

For much less then 50, IMO, new cables are well worth it
http://www.iboats.com/Johnson-Control-Cables

 

[oldboat1]

sounds like a good price. Agree it's better to replace a sticking cable, and better to just do both if one is clearly sticking, IMO. But maybe it's an assembly or adjustment issue.

I would first detach the cable connections at the motor. Make sure the throttle can be manually operated (engine in gear for full throttle operation) -- also that carbs are opening appropriately. For the throttle cable, make sure the set screws are tight if so equipped (no slippage), and the cable is secured in the clamp at the cowling.

With the cable detached at the motor, test cable travel that way (while clamped at the cowling). With the motor manually set at idle, and the remote lever at idle (neutral position), set the connector position to match the position of the engine throttle gear pin, using the knurled adjustment nut on the cable. (Don't reconnect to the throttle gear yet.) Then move the remote lever to WOT, and check the position of the cable guide. If you have significant movement and no binding, reattach to engine and try it (engine in gear for full throttle range). If you get some binding while the cable is detached, should replace the cable.