Topic: 1990 25 hp Johnson J25RESB neutral safety switch is acting up

This topic has 13 replies, 7 voices, and was last updated 7 years, 1 month ago by outboardnut.

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March 11, 2018 at 3:20 pm #9394
outboardnut
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At times when I go to start the engine it will not start.
I found when I push on the curved plunger which is located on the underside of the neutral safety switch the engine will start.
I found a way to slightly adjust the neutral safety switch.
The neutral safety switch is mounted by two brass screws on the left and right of the switch.
The right side hole is slightly slotted so I can pivot the neutral safety switch a bit down so number 77 will hit the curve plunger sooner.
Just so you know the neutral safety switch is not shown in any of the parts list. So I do not have a part number for the neutral safety switch. If you know the part number please enlighten me.
This is my fishing motor so I really need this engine to perform. I don’t want a band aid of a fix.
I’m thinking a few things.
1. Although the neutral safety switch works-Maybe the spring or contact is worn?
2.or that number 77 is worn(Cylinder & Crankcase diagram)
3.or that number 41 is worn(midsection diagram)
I’m thinking I need a new neutral safety switch .I just find it hard to believe that OMC would use that bad of hard plastic for cams on 77 and 41.
Any input will be appreciated.
https://www.marineengine.com/parts/johnson-evinrude-parts.php?year=1990&hp=25&model=J25RESB
March 11, 2018 at 3:39 pm #72353
crosbyman
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Canada Member
my lawn tractor acted up with similar symptoms (no neutral start due to wear ) which ended up being the contact surface area of the switch …

I solved it by beefing up the surface area pushing down on the switch itself

so and if you do not want to invest in a new part… can you beef up the surface area activating the switch itself if… that is not the bad part

Joining AOMCI has priviledges 🙂
March 11, 2018 at 9:06 pm #72373
fleetwin
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http://www.marineengine.com/parts/johns … +Crankcase
#91 is the neutral safety switch…
For now, you could always just ground the neutral safety switch lead, which bypasses the safety switch….
March 11, 2018 at 9:09 pm #72374
jerry-ahrens
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I have an older 35 Evinrude with that same switch. Mine started doing the same thing, I had a parts motor with a good one to swap over.
March 11, 2018 at 10:29 pm #72378
outboardnut
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Fleetwin I know I can bypass it but as they always said at work- safety first
March 11, 2018 at 11:55 pm #72382
crosbyman
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Canada Member
well time for a contribution for your hobby 😀

Joining AOMCI has priviledges 🙂
March 12, 2018 at 12:08 pm #72400
donsmarine
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Boats.net $30.00 #0386056
March 12, 2018 at 1:48 pm #72401
billw
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quote outboardfix:

Boats.net $30.00 #0386056

Agreed. Part number is in the diagram for electric starting accessory kit, if you’re looking for it..

Long live American manufacturing!
March 12, 2018 at 4:29 pm #72409
outboardnut
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The motor is electric starting
March 12, 2018 at 5:31 pm #72412
dan-in-tn
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Al; I know you gave me your model number as well as put it here, but your motor should be a J/E25TEESB. That stands for 25hp Tiller, Electric start, ES 1990 model, B is the suffix. (Could be for lots of reasons). The model you give should be a rope start (R) & the rest is the same. Not sure why your model is electric start at the motor? If you look at a J25TEESB on the cylinder/crankcase page #91 is the switch #386056. One on eBay for $22 OBO, Free Shipping. That’s pretty good, but I may have one.
Funny that two past service reps for OMC have now mentioned you can unhook it? That is not my first choice, but it will help you determine if that is the only problem. Like we talked about the switch is mounted on the ragged edge of engagement. Any little shim would make the switch/plunger engage more & therefore make the switch less touchy. It’s a common problem with this system. Plastic parts wear. A new switch may not alleviate all your problems. FYI

Dan in TN
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