How to Add a Recoil Starter to a Johnson 30 HP

Nothing is more frustrating than discovering the starter on your Johnson 30-horsepower outboard has a problem -- as you make the final preparations for an afternoon of boating. The fastest solution is to remove the old recoil starter and install a new one. If you have an extra starter on hand, replacement is a straightforward exchange of parts, with one minor adjustment.

Things You'll Need

  • Phillips screwdriver
  • 3/4-inch socket
  • Replacement recoil starter
  • Torque wrench
  • White marine grease
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Instructions

  1. Removal

    • 1

      Remove the screw that secures the starter lockout cable onto the back of the starter housing, using a Phillips screwdriver. Pull the lockout slide from the starter housing.

    • 2

      Loosen and remove the three bolts and lock washers from the recoil starter assembly to the top of the powerhead, using a 3/4-inch socket.

    • 3

      Remove the two bolts that secure the starter handle bracket on the powerhead, using a 1/4-inch socket. Lift the starter housing assembly from the powerhead.

    Installation

    • 4

      Align the replacement recoil starter over the flywheel so the three legs are positioned over the retaining bolt mounting bores in the powerhead. Position the lifting ring in place on the rear screw mounting boss.

    • 5

      Place the lock washers between the starter housing rubber mounts and the powerhead. Thread the three housing bolts into the mounting bores. Thread the two handle bracket bolts into their mounting holes.

    • 6

      Tighten the three starter housing bolts to 130 inch-pounds with a torque wrench. Tighten the two handle bracket screws to 72 inch-pounds.

    • 7

      Apply a thin coat of white marine grease to the starter lockout slide channel of the starter housing. Place the lockout slide into the channel and secure the cable using the clamp and screw on the powerhead.

    • 8

      Shift the motor into "Neutral." Adjust the lockout slide cable so the slide is centered on the lever. Tighten the cable clamp screw. Shift the motor into "Forward." Test the starter by pulling the starting handle. The starter must not rotate. Shift the motor into "Reverse." Perform the same test. If the starter rotates in any position but "Neutral," loosen the cable clamp and adjust the slide until the starter will not turn in "Forward" or "Reverse."