pulling flywheel 1961 40hp Johnson

[ward cleaver]

I am pulling the flywheel from my 1961 Johnson 40hp and I got to wondering if I need to remove the bolts that are on top of the flywheel first. The Selco manual doesn't mention these bolts. I have loosened the nut in the middle but as I was tightening the puller down I noticed these bolts. I assume I am ok to keep going without messing with those bolts but it would be nice to know from someone who has done this before.

 

[tx1961whaler]

Re: pulling flywheel 1961 40hp Johnson

Leave the perimeter bolts alone. They're just holding the toothed ring on the flywheel

 

[kfa4303]

Re: pulling flywheel 1961 40hp Johnson

10-4 on that tx. Leave them alone. The flywheel may be stubborn, but be patient she will come off. I usually tighten the puller bolt down down, then wait a bit, then tighten down a bit more, until the flywheel "pops" off. It will be loud and you may think you broke something, but that's normal. I would also leave the flywheel nut albeit loosened several turns just to prevent the flywheel from popping off all the way when it does come free. Also, be sure you reverse the direction of the wrap/strap when you go to tighten it back on and be sure that you tighten it down to the proper torque spec. You really don't want that thing coming off at WOT (unless you can duck really, really fast)! Once you get the flywheel off, the ignition is the same good 'ol OMC magneto system they used for years. You can clean and reset the points to .020, but I would suggest you just replace them. A tune up kit with points and condensers is only about $25 and worth every penny. I would also recommend you replace the spark plug wires. You can 7mm COPPER core wires (you can't use automotive graphite wires) at most NAPA stores (or other autoparts stores) for about $3 a foot. 6ft.-7ft. would be plenty for both wires. A couple new boots should only cost about $1.50. Be sure you twist them on to the coil posts rather than just poking them on there. You'll be amazed at what a difference it can make. Assuming the coils are good, if you replace the points, condensers, spark plug wires and spark plugs, you'll have a virtually new ignition system for less than $50 and it will be trouble free for years so shouldn't have to bother with taking the flywheel off again for a long time. These may help too. Good luck.

http://www.duckworksmagazine.com/03/r/columns/max/07/index.htm

http://www.duckworksmagazine.com/04/s/columns/max/24/index.cfm

 

[ward cleaver]

Re: pulling flywheel 1961 40hp Johnson

Thats what I thought. I'm on my second day of "letting it think about it". I'm in no hurry. Couple of tugs and a few squirts per day is my plan. Thanks for the links to the great article on tune up procedures. I've already got the points and condensers. Sounds like the plug wires, boots and plugs are well worth it too.

 

[tx1961whaler]

Re: pulling flywheel 1961 40hp Johnson

Might think about the coils also. If they are from 1961 they are done for. Let's put it this way: if you replace all of the components under there you will have a brand new ignition system that will go for the next 10 years without looking at it again. Skip one piece of it and you may be back under there next year.
100-105 ft-lbs on the flywheel nut when reassembling.

 

[nwcove]

Re: pulling flywheel 1961 40hp Johnson

hard to tell from the pic, but it looks like your puller isnt quite level?

 

[ward cleaver]

Re: pulling flywheel 1961 40hp Johnson

Ok, it popped up without as much effort as I was expecting. After removing the flywheel I was surprised to find a small piece of copper in there. See pictures. Any idea what this debris is from? Everything looks ok as far as the parts under the flywheel, nothing damaged as far as I can see.

 

[lindy46]

Re: pulling flywheel 1961 40hp Johnson

Maybe an old mangled spring clip that holds the two sections of the points together? That's about the only thing copper I can think of.

 

[Tim Frank]

Re: pulling flywheel 1961 40hp Johnson

^^^^
Sure looks like it.

 

[kfa4303]

Re: pulling flywheel 1961 40hp Johnson

Good guess Lindy46. I think you might be right. That's the only little copper piece I can think of that might be found near there. No telling what the PO did over the years. If the cam shaft and flywheel look ok, I would proceed.

 

[samuellewis]

Re: pulling flywheel 1961 40hp Johnson

Where can I find these parts? I have a 61 Johnson super sea horse, just pulled the flywheel and tried everything I know but cannot get a spark. Wires look pretty rough but all the points and coils look new(there not) Figure I will just replace entire ignition? As far as I know it has been since the early 90s since this thing has been started. Any help will be great

 

[kfa4303]

Re: pulling flywheel 1961 40hp Johnson

HI samuellewis. I would also just replace the ignition system too. If the coils look good, then they're probably ok. Start with replacing the points and condensers. You can get a tune up kit right here at iboats for about $25. Get come new 7mm COPPER core spark plug wire from NAPA or other autoparts stores. It's usually about $3 a foot. You'll need about 6-7 and a couple new boots ($1.50). Be sure you TWIST the new wires on to the coils post/spike, rather than just poking them on there. If you do all of these fixes, you will have a virtually new ignition system(assuming the coils are ok). You might as well get a carb kit and impeller too. You can get them both here also for about $25 a piece. For less than $100 you can replace all of the consumable parts which should give you a great running engine for years. Here are some great links that can walk you through all of the procedures. Keep us posted.

http://forums.iboats.com/showthread.php?t=158086
http://forums.iboats.com/showthread.php?t=167352
http://www.duckworksmagazine.com/04/s/columns/max/24/index.cfm
http://www.duckworksmagazine.com/03/r/columns/max/07/index.htm

 

[ward cleaver]

Re: pulling flywheel 1961 40hp Johnson

Is there a way to test the coils? I'd rather not spend $60 if I don't need to. But then I'd rather not pull the flywheel again either.

BTW nwcove the puller must not have been on exactly level because one of the grade8 bolts was bent a bit when I removed it. Unbelievable that you could see that from the picture!!

 

[samuellewis]

Re: pulling flywheel 1961 40hp Johnson

Thanks Kfa4303, I have already learned so much about these boats and motors and it has been a pleasure for the most part. I appreciate all the help. We will give this a try and go from there.

 

[nwcove]

Re: pulling flywheel 1961 40hp Johnson

there is a good video on utube, showing how to test your coils, just search for vintage outboard coils testing. all you need is a basic multi-meter and yer ready to go.

 

[nwcove]

Re: pulling flywheel 1961 40hp Johnson

lol ward, i guess my old eyes arent so bad afterall! pics are such a good tool for everyone here to use to help out with.......i think they're worth a couple hundred words.....maybe even a thousand! (and if you type with one finger, like i do.....a pic is worth at least a half hour!!)

 

[nwcove]

Re: pulling flywheel 1961 40hp Johnson

try this link http://www.youtube.com/watch?v=KT8rk5QWgS0

 

[ward cleaver]

Re: pulling flywheel 1961 40hp Johnson

Couple of things to report.
#1 I agree that the piece of copper debris is the (mangled) clip that goes on the points (since one of them was missing this clip)
#2 tested the coils while still mounted per the utube video and both tested bad (secondary). Did the disassembly to replace them and the plug wires and found that on the upper cylinder the plug wire had a bad connection at the plug boot and the lower cylinder had a bad connection at the coil. Retested stand alone coils and they both tested good (they are not original - these are made in Germany; in fact the points look like they were hardly used as well). So new plug wires, points and condenser but not new coils.
#3 looks like a botched tuneup by PO to me
#4 hope I do better

 

[kfa4303]

Re: pulling flywheel 1961 40hp Johnson

Good news Ward. Those are good replacement coils, and the points sound good, so I would get some fresh new 7mm Copper core spark plug wires from NAPA or another autoparts store for about $3 a foot. 6-7ft is plenty. That plus a couple new boots for less than $2 and you'll be good to go. Be sure you TWIST the new wires on to the coils rather than just poking them on. Clean/Set the points to .020" with the cam at the TOP position and you should be good to go. Sounds like the PO knew just enough to be dangerous. No worries. She'll be running in no time.

 

[ward cleaver]

Re: pulling flywheel 1961 40hp Johnson

I went to Orielly's and bought a couple of spark plug leads made by Omnispark. Then I checked online about the specs on them since it said nothing on the packaging and it seems most folks think they are pretty bad. How about a recommendation on what brand to get? These are automotive leads that I would be cutting off the plug on one end so I can attach it to the coil. Right? Thanks for the help.