Engine runs great, lower unit may be going now.

[teslaman]

Last Sunday, I took my rebuilt 73 115HP Johnson out to start the break-in procedure. The motor ran great and so did the lower unit, it shifted rather smoothly for an old system.

Today the motor still ran great, but the lower unit wouldn't switch into forward gear at idle. It acted like it wanted too, but the gears just didn't come together all the way. In order to get into gear, I had to push the throttle way forward which would start to rev-up the engine--I would then let off so I could motor at no wake speed. It also has trouble getting into neutral. For instance, after being in reverse and then setting the throttle to neutral, the unit was still in reverse. I had to shift the throttle lever past the neutral point and in the forward direction to engage neutral.

Now there is a lot more play in my throttle assembly than there was before the rebuilt. You have to push the lever forward at least 1/3 or more before any shifting begins. I did open the remote in order check some wiring and of course the cables where disconnected from the engine in order to install the rebuild.

Does this problem sound like a cable adjustment or like a bad clutch/gears in the lower unit. I sort of figured that I'd be buying a lower unit rebuild eventually, but I was hoping it would be a while.

 

[ezeke]

Re: Engine runs great, lower unit may be going now.

Sounds like cable adjustment - actually sounds like the cable has slipped in one of the casing gudes.

You might get someone to move the control throttle arm all the way from reverse to full forward while you watch what is happening at the engine - with the key in your pocket of course.

 

[teslaman]

Re: Engine runs great, lower unit may be going now.

Thanks ezeke, if an ajdustment needs to be made do I do it where the cables enter the powerhead?

 

[ezeke]

Re: Engine runs great, lower unit may be going now.

First, go the parts manuals and print out the diagram for your remote control and the parts list for the remote control.

http://epc.brp.com/default.aspx?brands=ej&lang=e

If the first test shows that the cable has slipped, disable the ignition - pulling the plugs is a good way.

Disconnect the shift cable casing at the engine.

Shift the gearcase to forward and reverse manually while either turning the flywheel clockwise, or having someone turn the propeller. This should assure that the gearcase is working.

The shift cable is held in place by two opposing set screws in the Casing Guide. If they are over tightened the cable can be cut.

If they are too loose, the cable will slip.

Once you are satisfied that the gearcase is shifting with the cable off you need to fix the cable.

Shift the gearcase into neutral, and then move the throttle lever all the way forward and back to neutral, the start position. Use an Allen wrench to loosen the outer set screw on the cable casing slightly and then reconnect the cable casing. Tighten the cable casing set screw, being careful not to over tighten.

If the slip is at the engine, this process should fix it. If it does not, the cable is either broken, or is slipping inside the control.

 

[teslaman]

Re: Engine runs great, lower unit may be going now.

I did exactly what u said, but instead of tightening the cable I adjusted the cable using the plastic wheel where the cable enters the powerhead. I hooked the muffs to the engine, started it, and switched to N, F, N, R, N, without any problems. I hope it works in the water like that.

I may have not fixed the actual problem though. If the cable slipped before, then it will probably slip again. What do you think?

Thanks for the help ezeke.

 

[ezeke]

Re: Engine runs great, lower unit may be going now.

If it holds you may be OK.

If not, you know where the set screws are. If it were me, I think I would tighten the set screw a little. You don't want it to slip while you are on the water.

The good news is that the gearcase sound like it is OK.

 

[teslaman]

It works great now.

It works great now.

I took the boat out yesterday for some crappie fishing and the shifting worked really well -- I even got into a few crappie!

I did tighten up the screws/crimpers just a little on the cable guides before I took it out just like you suggested.

Thanks for the help ezeke.