Replacing Johnson 90 Hp Throttle Control: A Step-By-Step Guide

If you're looking to replace the throttle control on your Johnson 90 hp boat, there are a few options to consider. Firstly, it's important to determine the model year of your engine as different parts and controls are compatible with specific years. For example, the BRP Johnson Einrude Outboard Remote Control with tilt control (B001KXTWW) is recommended for engines from 1996 onwards.

You can also refer to the Crowley Marine website, which provides detailed instructions on throttle cable replacement for Evinrude E-TEC 40 – 115 HP model outboards. They recommend that safety precautions are taken and that replacement parts are genuine Evinrude/Johnson parts or equivalents.

Additionally, Amazon offers a variety of throttle cables compatible with Johnson outboard engines, with specific products catering to different model years.

It is always recommended to consult a professional or authorized dealer when performing boat engine maintenance or repairs.

Removing the throttle cable anchor screw and washer

To remove the throttle cable anchor screw and washer from a Johnson 90 hp boat throttle control, follow these steps:

Begin by twisting and removing all spark plug leads to prevent accidental engine starting during the repair. Then, use the remover tool with the part number 0342226 to unsnap the throttle cable clip from the throttle lever. This will allow you to access the throttle cable anchor screw and washer.

Next, remove the throttle cable retainer, which holds the cable in place. With the retainer removed, you can now take out the throttle cable anchor screw and washer. Be sure to set them aside in a safe place, as you will need them again when installing the new cable.

After removing the screw and washer, continue with the rest of the throttle cable replacement procedure, ensuring that you follow the correct safety guidelines and refer to the appropriate service literature for your engine.

Disconnecting the stop switch electrical connector

Firstly, for safety reasons, it is highly recommended to remove all spark plug leads to prevent accidental engine starting during the repair process. This is a crucial step to ensure your safety while working on the engine. Next, locate the stop switch cover screws and remove them. You will find these screws securing the stop switch assembly in place. Once the screws are removed, you can proceed to the next step.

Now, carefully disconnect the stop switch electrical connector. This connector is responsible for providing power to the stop switch, and it is essential to detach it before removing the assembly. Take your time with this step to avoid any damage to the connector or the surrounding components. Once the electrical connector is disconnected, you can proceed to remove the stop switch assembly.

At this point, you should be able to lift and remove the stop switch assembly from its housing. Be gentle and take note of how the assembly is positioned for reinstallation if needed. With the stop switch assembly removed, you now have access to the internal components and can continue with the replacement or repair process. Remember to keep all removed parts in a safe place for future reference or reuse.

It is important to note that working on boat engines can be complex and potentially dangerous. Always refer to the official repair manuals and instructions provided by the manufacturer. If you are unsure or uncomfortable with any part of the process, it is best to seek assistance from a qualified marine mechanic or authorized dealer.

Removing the throttle cable retaining clip

To remove the throttle cable retaining clip, you will need to follow these steps:

Firstly, ensure you have removed the throttle cable anchor screw and washer, as well as the cable retainer. Now, you can move on to removing the throttle cable from the grommet in the lower engine cover. It is important to loosen the throttle friction control at this stage, so there is no restriction on the grip. However, do not back screw out completely, as the nut is under spring tension.

Next, you will need to remove the seven screws and bottom cover of the tiller handle. This will allow you to access the inner workings of the throttle control. With the bottom cover removed, you can now disconnect the stop switch electrical connector and remove the stop switch assembly.

At this stage, you are almost ready to remove the throttle cable retaining clip. First, though, you must remove the trim switch connector and depress the grip detents using a twist-grip remover. Now, carefully pull the throttle pin out of the cable. Finally, you can pry the cable trunnion out of the steering handle and remove the cable.

The throttle cable retaining clip should now be exposed and ready for removal. Ensure you have all the necessary tools and take your time during the process to avoid any damage to the boat or engine.

Installing the new throttle cable

To install the new throttle cable, you will need to follow these steps:

Firstly, remove the old throttle cable by unsnapping the throttle cable clip from the throttle lever using a remover tool. Then, take out the throttle cable anchor screw, washer, and cable retainer. Next, loosen the throttle friction control and remove the cable from the grommet in the lower engine cover.

Now, you can install the new throttle cable. Begin by placing the handle end of the new throttle cable into the recess in the handle and securing it with a new retainer clip. Push the throttle cable pin through the end of the throttle cable and lubricate it, along with the guides, rollers, helix halves, and inner steering handle.

Place the guides and rollers in their respective positions, ensuring that the wire guide is in place in the inner steering handle. Be careful not to twist the trim switch wiring. Pull the trim switch wires carefully through the inner tiller handle as you install the twist grip assembly.

Finally, connect the trim switch connector and snap the grip into place, ensuring that the indicator line is aligned with the speed range symbol on the handle.

Adjusting the throttle cable

To adjust the throttle cable on a Johnson 90 hp boat engine, begin by routing the throttle cable through the grommet in the lower motor cover. Apply soapy water to the cable and the inside surfaces of the grommet to ease the process.

Next, use a Ball Socket Installer tool to snap the throttle cable connector onto the throttle lever. Place the throttle cable in the upper anchor pocket and install a new cable retainer on the anchor block.

Now, hold the twist grip in the full 'SLOW' position and pull firmly on the cable to remove any slack. Adjust the cable anchor so that the throttle cam is against the idle stop when the throttle cable anchor aligns with the mounting hole in the throttle body.

Finally, rotate the anchor four turns towards the end of the cable. Install the washer, cable anchor, and cable anchor screw on the throttle body, tightening the screw securely.

Check that the throttle cam goes to full throttle without bending the cable and that it returns to the IDLE stop.

Frequently asked questions