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2004 Johnson 225 hp Outboard does not crank

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Palestro

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I bought a Sea Boss with a 225 HP Johnson Outboard (2004). I had it shipped from Florida to Muscat, Oman. The dealer tells me, before shipping, the boat was in great shape and the motor was as well. The motor looks super clean as new. I can not get the engine to crank. It looks like no juice is getting to the starter. I had a mechanic and an electrician look at the motor, neither one seems to identify the problem. I made sure, the lanyard was clamped on properly with the key pushed in, Throttle in neutral, I took the throttle out and checked all the connections were good. The current gets to the horn, the bilge pumps, to the lights inside the cabine etc... Everything I could think off was checked with an voltmeter/ampmeter. The motor crancks if a wire is used to suply the current directly from the battery. The mechanic is suspecting the Motor Control Modulator might be defective. I welcome any suggestions from anyone out there who experienced this problem. I ordered the users manual, but it will take over a month to get it here. I spend over 26,000 dollars to buy the boat and have it shipped over here, I am stuck and running out of ideas. HELP...Help...help... Thank you.
 
Re: 2004 Johnson 225 Outboard does not crank

A couple of possibilities, but nothing big.
Best if you have a volt meter, but 'manual' testing may even work.
1: Ignition key.
When turned to start, do you have 12 Volts at the yellow/red?
2:The yellow/red from key goes to control box. Inside the box is a switch that gets activated when i neutral. If not in neutral, no 12 volt to solenoid. When key in start, check you have 12 Volt out from remote control box.
3.Starter relay.
There are 2 'small' terminals. One with 2 yellow/red, one goes to ground.
One of the yellow/red goes to remote, the other to Power-pack to initiate Quick start.
Do you have 12 Volt in the one coming from the control box when key is in start?
If 12 Volts out of box but not at the relay, check all plugs and connections.
If you have 12 Volts at starter relay, but no 'click', relay is probably defective. Test by connecting the volt meter to the terminal (big) going to starter motor. It should be 12 Volt,(may drop to about 10,5 when starter cranks).

Good luck.
 
Re: 2004 Johnson 225 Outboard does not crank

Run known good cables from a known good fully charged battery directly to the starter. Does this cause the starter to crank the engine over as it should?
 
Re: 2004 Johnson 225 Outboard does not crank

Thank you very much for the suggestions. I will follow your instructions tomorrow (GMT + 4 hrs) and will revert. Have a great day...

Best Regards
 
Re: 2004 Johnson 225 Outboard does not crank

Dear Helpers,
We did all the tests and followed your suggestions. All checked good, We found that the curent suply from the Ignition to the Engine Control Module is OK at 12 volts, but from the ECM no current is going to the Starter Relay. The electrician strongly suggests to replace the ECM. Is there any Hardware and software available to check the ECM? The only Johnson representative here in Oman is Evenrude but they do not market the Johson Outboard so none of their technicians are familiar with Johnson.
One more question, the engine I bought was first purchased in 2004, is the warranty still valide, I read somewhere that the warranty is good for seven years. How will I proceed to get the benefit of that warranty?
Thank you for your appreciated help.
The answer to the second question is Yes the engine cranked when the Starter was directly connected to the battery.
 
Re: 2004 Johnson 225 Outboard does not crank

HOLD IT!
There are no current going from 'ECM' to start relay!!!!!
It is not an ECM but a power pack.
The yellow/red FROM relay to Power pack is just to activate Quick Start!!!!
For safety reason at the moment, remove the yellow/red going to power pack and leave only the one coming from ign switch/remote control.
Hold the key in 'start'.
Measure between yellow/red and ground ONLY!
1 Do you have 12 Volt out from ign switch at the back?
2.Do you have 12 Volt INTO the control box?
3. Do you have 12 Volt out of the control box?
4. Do you have 12 Volt at the starter relay?
If You have 12 Volts all the way - the relay is gone!
If You have 12 Volt into the control but not out, try to 'wiggle' the handle. It might be a failure in the switch inside.
If you have 12 volts out of the box but not at the relay, check connectors in extension harness both at control side or at engine.
When getting back, please give the readings you get on the above measurements.
 
Re: 2004 Johnson 225 Outboard does not crank

If there is a Evinrude dealership in Oman, and the technicians know what they're doing pertaining to the Evinrude engines, then they would be very familiar with the Johnson engines.

Evinrude and Johnson engines are identical except for the paint job and possibly a hood design...... a slight difference such as between the Mercury and Ford automobile.

Check for a inline fuse a short distance from the electric starter solenoid in the yellow/red wire. If faulty, replace it.

Remove, clean and then retighten all cables/wires pertaining to the electric starter. This includes the battery terminals, battery selection switch, starter solenoid, and battery cable ground(s) at the powerhead. Many a time this problem occurs due to no other reason than a loose or tight but dirty connection. Clean the cable/wire terminal ends as well as the component they attach to.
 
Re: 2004 Johnson 225 Outboard does not crank

What do you mean when you say: "It is not an ECM but a Power pack" , on the wiring schematics is shows it as "Engine Control Module" I got the schenatics from Richard from Enginemarine.com. How can I e-mail you the Electrical Wiring diagram, maybe I will understand better and follow your suggestion better. Thank you for your help.
Regards
 
Re: 2004 Johnson 225 Outboard does not crank

The power-pack takes its charge and signals from coils under the fly-wheel.
It is not connected in any way to the boats 12Volt system except for the initiating signal for Quick Start which is a pure timing issue.
If you have the complete diagram, just follow the yellow/red, but 'forget' about the one going to the power-pack.
Click my name and you should get to my CP and e-mail.
 
Re: 2004 Johnson 225 Outboard does not crank

I am talking about the Engine Control Module that the electrician is recommending to replace. I am not sure we are talking about the same part...
 
Re: 2004 Johnson 225 Outboard does not crank

Johnson 225 does not have an 'Engine Control Module.
It is an old fashioned carburetor engine.
You may find all parts here going to: evinrude.com.
The powerpack has nothing to do with the cranking circuit.
Your 'electrician' only has to measure/test as described above.
A short test for the solenoid:
Take a 5" cable and attach to the big stud where battery cable is attached at the relay.
Shortly touch it at the small where the yellow/red is attached.
Does the starter kick in?
 
Re: 2004 Johnson 225 Outboard does not crank

Are we perhaps talking about a Johnson 2004 4 stroke here? Maybe you can post a model number.
Thank you
 
Re: 2004 Johnson 225 Outboard does not crank

Are we talking about a 2004 johnson 4 stroke? Please post a model number.
 
Re: 2004 Johnson 225 Outboard does not crank

Most likely!

In that case the shift position switch at the shift linkage is normally the culprit.
If engine shift system is not in neutral, engine will not start (crank).
Might be wrongly adjusted shift cable or defective switch.
 
Re: 2004 Johnson 225 Outboard does not crank

Here a pic of the switch assy:
From pos 1 to 8.
 

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Re: 2004 Johnson 225 Outboard does not crank

Good afternoon Haffman37 and All.
The picture you attached is exactly what I am talking about. The Model number for the engine is J225PX4SR, the serial number is S 31024011. The motor is Four Strock. The electrician is suggesting to change item number 18 on the picture. There is no voltage from Item No 18 to the starter motor relay...
Thank you for your time and help.
 
Re: 2004 Johnson 225 Outboard does not crank

If possible, send me the chart by e-mail.
I sent you my e-mail address by PM.
Dis your electrician check out the neutral start switch at the engine?
( Pos 1-8)
As far as i remember, been some time since last, the activating of the relay is not going through the ECM, however the ECM may block the relay from being activated IF engine is running.
I would need the chart to be sure.
 
Re: 2004 Johnson 225 Outboard does not crank

Note that this is not a genuine Johnson engine, but a re-painted Suzuki!
All technical parts are identical with Suzuki. I see from Google that there are dealers both in Quatar and UAE that should have the parts you eventually would need.
 
Re: 2004 Johnson 225 Outboard does not crank

Got the diagram, but to be able to keep size and resolution, I have uploaded it here:
http://www.box.net/shared/khvva32yqp
The circuit is strait forward.
From key to engine, the 'normal' Johnson. Start signal + in the yellow/red cable.
Entering the engine, it switches to Suzuki color, Brown!
Then through the neutral start switch (must be closed/shorted when in neutral to work) to starter relay.
Note that this relay (primary) is grounded in the ECM, ref pos1 in the right connector. No current should go FROM ECM to relay.
With engine running, this ground is 'open' to prevent starter to be engaged with running engine.
Check pin#1 for ground in the right ECM-connector (the smaller) in the diagram.
Secondary in relay is B+ (White) and Starter Power,(Red).
 
Re: 2004 Johnson 225 Outboard does not crank

Got the file in PDF and had to convert it to JPG.
A bit 'murky' as reduced from 835 Kb.
Trying a direct upload:
 

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Re: 2004 Johnson 225 Outboard does not crank

I took a brake from the boat. I will start investigating again in a couple of days, I will post the findings. Best Regdars
 
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