Re: 77 johnson 25 hp still having problems?
csgrizz - you have a few options:<br />1) turn around the clutch dog so you use the reverse ears - this only works if the dog is symmetrical. If it's not, it'll jump worse than before. Sometimes the ear face has a very slight angle cut into it, about 1° or so.<br />2) Buy a new clutch dog - They're not as expensive as I first thought. Seems they go for under $50USD from the dealer. But if the forward gear is also worn out and needs to be replaced, then it gets expensive.<br />3) Regrind the foward gear and clutch dog. You'll need to employ the services of a machinist, and he must remove as little material as possible. These are case hardened parts, and going too deep will go through the hardened layer.<br /><br />The worn dog is caused by either a mis-adjusted remote shifter, or much more commonly from slow shifting. Many people make the mistake of thinking they are being easy on the engine by easing it into gear, when really it needs to be thrown into gear with gusto. It also seems to me that the 15-18-20-25hp (22.0cid) engines are particulairly bad for having worn dogs.<br /><br />If you pull the shifter forward while this is going on, it may stop or at least you may feel the dog jumping through the lever to prove this is the problem. Also, remove the shift linkage access window and make sure it's shifing the lower unit fully into forwards. It's unlikely that this will solve your problem though.<br /><br />Good luck!
