9.9hp gear trouble...

Waco

Petty Officer 2nd Class
Joined
Jan 2, 2002
Messages
138
Okay, I will need some of yall's expert advice on this one! I ran a 9.9 Johnson this weekend. (thinking about buying it) Motor runs great at all ranges, no skips, no spitting..anyway, between half and full throttle (under pressure I guess) It would act as if it wanted to jump out of forward gear. It never did jump back to neutral, but I would, for a split second, quit pushing. It felt like the foot was hitting bottom, but I know that was not the case. It did this every 5 or 6 seconds. Next, I found that if I put a small amount of forward pressure on the gear control, it ran like a champ, no problems, no trying to jump out of gear. Next, I pulled the cover and looked around. (I am mechanical, but new to these things) There is an adjustable linkage in there coming from the control lever to a pivot point with notches in it that tell the operator that the the motor is in gear. I lengthened the linkage (about 3 rounds) in hopes of exerting more pressure on the forward position. I ran the motor again. It helped a lot, but still would try to jump every now and again, (say, once every two or three minutes). The linkage is close to being out of threads, so I dont think that is an option. How can I remedy this? Is there another adjustment? Is there a chance that something serious is wrong with the motor? Please give me some feedback. Thanks!
 

Fouled Plug

Ensign
Joined
Jun 29, 2001
Messages
935
Re: 9.9hp gear trouble...

Sounds like the classic symptoms of clutch dog wear in the lower unit. The repair, unfotunately, is expensive as you must replace the clutch and forward gear at the same time. The clutch dog ears tend to wear on the edges and they start popping in and out of gear. If that's your problem, I'm afraid it'll only get worse. :(
 

Waco

Petty Officer 2nd Class
Joined
Jan 2, 2002
Messages
138
Re: 9.9hp gear trouble...

hmmm...didn't really want to hear that. Are there any other possibilities? This motor has very hours on it. Even the original prop still has most of the paint. <br /><br />Thanks Fouled Plug for the input.
 

Fouled Plug

Ensign
Joined
Jun 29, 2001
Messages
935
Re: 9.9hp gear trouble...

Well, I spose you can check the gear lube for lots of water. Or maybe the linkage is really really out of whack. But your symptoms are classic for a whipped clutch.
 

Waco

Petty Officer 2nd Class
Joined
Jan 2, 2002
Messages
138
Re: 9.9hp gear trouble...

I can't spell or type today. sorry about the typo earlier. The motor has very FEW hours on it.. :) I changed the oil in the lower. The oil that was in it looked good. I guess I'll start tearing it down this weekend to see whats going on. Thanks again.
 

Fouled Plug

Ensign
Joined
Jun 29, 2001
Messages
935
Re: 9.9hp gear trouble...

Waco, lets see if anyone else has any other ideas. I may well be overlooking something. Even if you did an inspection, the "ramping" of the gear and clutch is subtle and hard to see. I'm interested to hear any other ideas out other members may have.
 

bdavis

Recruit
Joined
Dec 30, 2001
Messages
5
Re: 9.9hp gear trouble...

I have a 89' Johnson Sail Master and just had the lower leg dropped to replace the water pump. As I recall, there is a shift linkage rod that must be un-fastened to drop the leg. When re-assembleing the Manual talks about re-adjusting the gear shift linkage throw. Maby that's the problem.<br /><br /> Good Luck
 

Waco

Petty Officer 2nd Class
Joined
Jan 2, 2002
Messages
138
Re: 9.9hp gear trouble...

I hope that is the case. The guy that had the motor said the water pump was replaced a while back. (the engine had been sitting for quite awhile)
 
D

DJ

Guest
Re: 9.9hp gear trouble...

Waco,<br /><br />I'd bet a fish dinner that the clutch dog is gone.<br /><br />This happens quite frequently on engines that were consistantly improperly shifted.<br /><br />Some owners "think" they are saving themselves problems by shifting SLOWLY. A clutch dog type shifting mechanism fails quickly when that method is used.<br /><br />Outboards (and MerCruisers) should be shifted quickly and surely into gear.
 

Waco

Petty Officer 2nd Class
Joined
Jan 2, 2002
Messages
138
Re: 9.9hp gear trouble...

If the clutch dog is gone, will it be obvious when I (or who ever)gets in there? I haven't ever torn one apart. I'm trying to find a manaul now.
 

Waco

Petty Officer 2nd Class
Joined
Jan 2, 2002
Messages
138
Re: 9.9hp gear trouble...

I had a mechanic break it down for me and take a look. The way he explained it me was like this: There is small bearing on top (one individual bearing) and one the bottom, of the clutch. He says that putting it together without losing one is pretty tricky. Well, obviously, the last person that put it together lost one, and that was causing the problems. He said the clutch dog, forward gear, etc.. looked to be in good shape. I guess I'll find out this weekend! <crossing fingers>
 
D

DJ

Guest
Re: 9.9hp gear trouble...

Waco,<br /><br />That will do it too. Didn't know anyone had been "fishing" in there.<br /><br />Glad you got it figured out.
 

Waco

Petty Officer 2nd Class
Joined
Jan 2, 2002
Messages
138
Re: 9.9hp gear trouble...

Just wanted to let everyone know that I ran the little booger this weekend, and it ran like a new one. No problems whatsoever. And, it didn't cost me a dime! Thanks for all the responses and words of advice. <br /><br /> :D
 
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