25HP Johnson jumping out of gear

[slader99]

This was originaly in someone elses thread, moved as I may have been hyjacking.

Had a question and after searching the forums found this post was probably the most suitable place. I have a 91' Johnson 25 horse (J25RWLEIM) which is kicking out of gear. When I purchased it I ran it in a bucket and it seemed fine but on the water withn @ 1/3 throttle in FWD it kicks out of gear. Holding it in gear doesn't seem to help much and I didn't want to shread my gearcase.

Popped the gearcase apart and damn'd if the detent balls were missing. There was silicon on the gearcase which makes me think someone had it open before decided the balls weren't neccisary. While I was at it I took a look at fwd and the clutch dog, they both showed wear but it didn't seem excessive. (it looks like a dog and gear for this thing would run me over $300). I took pictures of both edges of the fwd gear and dog, there seems to be a void in the fwd gear surface, it doesn't rellay look like it was caused by wear, it looks like a material defect

I have two questions
1) Do you think this clutch dog needs to be replaced given the photo below,
2) I've heard people say to orient the side of the dog with the least wear facing the fwd gear, but the dog also has a grove around the diameter of it which I have been told needs to be facing the fwd gear.... it looks symetrical, does it matter or not?

Sorry for the essay,

Colin

 

[tashasdaddy]

Re: 25HP Johnson jumping out of gear

replace it all it is going to do is tear up other stuff. what causes this is slow shifting. you do not ease it into gear, you slam it into gear, this cuts down on the wear. that chunk out of it is horrible.

 

[wilde1j]

Re: 25HP Johnson jumping out of gear

As I told you in the other thread, you have junk ... replace all.

 

[slader99]

Re: 25HP Johnson jumping out of gear

You also told me to create my own thread so I did....

Thanks for the advise guys. I know there was wear on the dog, but it was only like 1/32" radius, a friend showed me a couple dogs he had pulled out of functioning gear cases that had closer to 1/8" radius so I was hoping I could save myself $140 for a dog....

As for the alignment of the dog, does the marking around the diameter of the dog need to face the fwd gear? If it does, could you please explain why as the dog looks symmetrical and I've found posts contridicting each other.

Thanks,

Colin

 

[samo_ott]

Re: 25HP Johnson jumping out of gear

Huh. That wear doesn't look too bad to me, I've seen worse that worked fine but I will defer to others that have seen more. The chunk missing is bad though.

 

[wilde1j]

Re: 25HP Johnson jumping out of gear

The gears need replacement also, not just the dog.

 

[slader99]

Re: 25HP Johnson jumping out of gear

assuming the dog and gear were in very good shape, can someone explain if the orientation of the clutch dog matters, and why?

I am asking this because I have heard contridicting info (face least wear toward fwd gear/ face clutch dog diameter marking toward fwd gear).

thanks,

Colin

 

[wilde1j]

Re: 25HP Johnson jumping out of gear

Shop manual for your motor (which I don't have) will explain correct orientation.

 

[dave1]

Re: 25HP Johnson jumping out of gear

as i have learned in the past. make sure also you don't have any play in the linkage. worn bellcrank or worn shift rods. my 40hp had this problem.looked at the gears for days when the problem was in the worn linkage.

 

[slader99]

Re: 25HP Johnson jumping out of gear

dave, how did you diagnose the play in the linkage.... inspection or did you need to button up the gearcase first?

 

[dave1]

Re: 25HP Johnson jumping out of gear

im assuming yours has mechanical linkage. some models don't. when lower units off grab linkage and see if theres any up and down play?then you need to see where its coming from.

 

[igadget56]

Re: 25HP Johnson jumping out of gear

dave1 where is the bellcrank located, do you have a part#.