Johnson K45 exhaust

[Goman]

I found this piece down in the exhaust down pipe covered in carbon. I was looking for a parts list, picture or diagram on how this system was put together. I understand that the system didn’t work well and people would undo it through the years. I’m mostly just wanting to close the holes off and make it look better. And/or if parts are out there fix it the way it was originally.
Thank You
Glen

[Tom]

To get it back to original, you’ll need the screw on cover for the hole in the photo, as well as the spring and pin retainer for the other end of the "valve stem". Then on the tiller bar, you’ll need the release lever / clamp assembly. I just got a set of castings from Art DeKalb and finished this job on mine, it works very well. For the cable, don’t use the original solid wire inside the spiral wound cable. Use a stranded wire inside a lined outer spiral wound cable. I used something from a lawnmower clutch cable that was perfect, and I have a leftover piece that’s long enough if you need it. It takes a lot less effort to open the valve, friction is a lot lower, and you don’t have to worry as much about bends in the cable.

Let me know if you need photos or more info.

Tom

[Goman]

Thanks Tom. I believe I understand the set up now. I may be able to find a pipe plug and drill a hole through the center to run the cable through.
What I can’t understand what’s the purpose for this set up?

[bob-d]

Tom, I have a K45 as well with the same missing tiller bar lever arrangement.
I picked up Arts castings, but never finished the job.
I would love to see pictures of your finished tiller lever setup, and routing of your cable. The only picture ( drawing) I have ever found of a complete setup was in the back of the big red cover Johnson Service manual 10th edition page 613.
Goman, I believe it was used to reduce the back pressure to make the engine easier to pull when starting.
Thanks.

[Tom]

I will take some pics tonight and post them.

T

[Goman]

Also on the other lever I understand the compression release part but what does the part inside the top part of the motor do?
Thank You
Glen

[Tom]

Here are photos of Art DeKalb’s castings machined and installed. The castings are an alloy that machines very easily. I’m not sure its machined or installed as per original, but it fits and it works. I didn’t have any original parts to use as a pattern, and the Johnson parts drawing doesn’t show their relative orientation.

The cable is part of a blade clutch cable from a Toro mower. It’s a lot more flexible than the original, since the stiff steel wire is replaced by a braided cable. The sheath is lined inside with some type of plastic, so it slides freely.

The contraption on the top of the compression release cylinder closes off the bypass port on the starboard cylinder. This forces more fuel / air mix to the port cylinder for starting. Similar system was used on the S, P, and V series motors.

Hope this clears it up.

Tom

[The Boat House]

I have seen and bought a couple of Arts
rough castings and they are just that,
rough castings. Nice work.

[Goman]

Thanks all! I can quit scratching my head for now. I found a fella running one on you tube.
Glen
https://www.youtube.com/watch?v=xTnGegKKCpA

[bob-d]

As Tubs said they are rough to start out. thats why I never finished mine.
Tom thanks for the pictures. I will take another shot at it, now that I have your pictures.

[Author]

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