Johnson Control not Going into Reverse

[urb]

I have 200 HP Evinrude 1987 OB. The controller will occasionally not go into reverse - even though the handle will move into the reverse position the engine will still be going forward. I have to jiggle it and "play" to get it to work. Doesn't happen all the time either. Very intermittent. A little on the annoying - and dangerous - side.

Took it to a mechanic and they found nothing wrong.

Any ideas?

 

[gm280]

First thing, Welcome aboard urb :welcome: Glad to have you join us...

Sounds like it could be a number of things. First, is the cable going to the actual shift lever okay? Can you disconnect the shift cable and so if the control works without any resistance? If there is resistance, the cable could either need greased or replaced. If that cable is good, have you actually checked the cable connection in the control box? If that cable ever got bent, there will be issues with it when it feel like it. Even the cams inside the control unit could be worn. If all those things are good, check the actual shift linkage to the lower foot. Does that work freely as well. Any of those parts that have wear and can cause such things. So you have a number of things to check out and get back to us here. And I ask you, either way you find things or get it fixed, please reply back on here so others can see what fixed your problem. Then we all learn... JMHO!

 

[urb]

Thanks gm280. I appreciate the feedback. We've had some bad snow here so won't be able to get to it for a bit but certainly will let everyone know if I find anything

I assumed the boat mechanic I took it to checked it out but I'll talk to them again and ask about your issues. I just got the boat late last year and went through the engines: cleaned the carbs, replaced the stator, water pump... runs pretty good (still has an intermittent overheat alarm at WOT but can run at 50 with no issues). The controller only seemed to act up when I was in a tight place - at the dock, near a rocky shore - you know worse possible time... so I was not able to really figure out what happened. When the weather clears up we'll get on it

I just wasn't comfortable with the controller and all the springs and little parts but I guess I need to give it a try. They only charged a $130 to look at it but like I said they found nothing...

Anyway, thanks and look forward to getting this figured out - for everyone.

 

[fireman57]

Mods, I am helping work on this boat and was wondering if you could move it to the Johnson/evinrude repair forum. I believe it will get better traffic there. Thanks.

 

[urb]

Just for the record. It turns out that the plastic gears in the control box had some broken teeth that prevented it from shifting out of gear. The broken parts were also interfering with the movement so at times it would "stick" and I had to jiggle the handle to dislodge them. Luckily we had a spare control box which had other issues but the gears were good. The boat mechanic put them in and got everything working for a couple of hundred dollars. Seems to be fine now.

 

[gm280]

Just for the record. It turns out that the plastic gears in the control box had some broken teeth that prevented it from shifting out of gear. The broken parts were also interfering with the movement so at times it would "stick" and I had to jiggle the handle to dislodge them. Luckily we had a spare control box which had other issues but the gears were good. The boat mechanic put them in and got everything working for a couple of hundred dollars. Seems to be fine now.

Glad to read you got it fixed now. And thanks for reposting the problem as well. That helps others if they have a similar issue... Happy boating... :thumb: