I sheared a bolt head and cant drop lower unit

[waynehol]

1988 Johson 90 HP

Well, I have a book and it says nothing about what this cover is for. (see photo) I sheared the head off the top right bolt. How do I remove it and what is that cover for?

Also, I searched these forums and found out about disconecting the shift linkage under the bottom carb. My book says nothing about that! Im going out now to see if I can figure it out. It dropped about 3/4 inch and no more so I guess it is this linkage.

Thanks for your help~!!

 

[mattinglyt]

Re: I sheared a bolt head and cant drop lower unit

Probably the easiest way to get the bolt out is to see if the cover will come off now that you've got everything out of the way. There may be enough bolt exposed that you can get some vise grips on it. I suggest trying to heat the bolt a bit w/ a torch first to break the rust free. Oxy/acty is a preferred torch, but a small propane torch may do the trick too. If you don't have a torch spray it w/ some good penetrating oil and let it sit for awhile and keep spraying it. Then try the vise grips.

Now if you cannot get to the exposed bolt, or there is none exposed, you'll have to drill it or take it somewhere to have it done. If you do it, MAKE SURE YOU CENTER PUNCH IT IN THE MIDDLE!! If not and you drill it off center, your problem just went to crap. If you've never drilled out a broken bolt and used a tap to clean the threads or over drilled it and installed a heli coil, then I suggest paying someone the small fee it will take to get it done right BEFORE it is a problem.

By the way, smile and have fun

 

[ezeke]

Re: I sheared a bolt head and cant drop lower unit

Behind the part that you are attempting to remove is a rubber coated lower mounting bracket which does not require any routine servicing. The bolts are simply holding a cover and the broken one will not greatly affect the utilty of the bracket. Because the part into which the bolt enters is heavily rubber cushioned, I would recommend against the use of heat, and have a machinist remove it when you have time.

 

[ezeke]

Re: I sheared a bolt head and cant drop lower unit

The shift rod disconnect is under the carburetors, inside the engine compartment.

 

[waynehol]

Re: I sheared a bolt head and cant drop lower unit

Thanks so much for the help. I think I will get someone who knows what they are doing to remove the bolt.

As far as the disconnect, I dont see anything under the lower carb. I looked in my book again, and found out what to do. It said remove the starter (I did) and the disconnect would be under the carb but dang if I dont see it! I guess I will remove the carb and see if I can see it. I wish I had known about this when I removed and cleaned the carbs! Oh well, part of the learning experience.

Thanks again!!

 

[ezeke]

Re: I sheared a bolt head and cant drop lower unit

Look on the bottom starboard side of the engine for a clip. Pull the clip and the lever will slide to release the shift rod.

The shift rod itself is centered exactly between the sides of the lower cover; if you shift, you can see it rising and falling.

 

[waynehol]

Re: I sheared a bolt head and cant drop lower unit

Whew got it finally. Thanks for the tip! Putting it back was another story all together but I finally got it. Working great!