clutch dog issue(maybe?)

[jpatterson12]

I recently bought a '65 Johnson 9.5 hp Seahorse. It was tough to start, and ran rough, but I figured a carb kit and a tune up would do the trick. While I was at it, I changed the impeller. Once I got it back in the water, I found that at anything above idle speed, it popped out of forward gear. I dropped the lower unit and checked the shifter linkage, in fact I've had it apart several times but still have the same problem. before I crack open the gear case to check the clutch dog, does anybody have a tip that I may have missed. As you can tell, I'd rather not open that gear case if I can avoid it. May not have a choice.
Thanks,
Jon

 

[Joe Reeves]

Re: clutch dog issue(maybe?)

Assuming that there is no play in the shift linkage between the shift handle and the brass shift connector..... that problem can be caused by NOT having the grooves in the shift rods perfectly aligned with the bolt holes in the brass shift connector. Double check that alignment.

If there is no shift play and the rod grooves are aligned as above, I'm afraid that you're due for a lower unit inspection.

 

[F_R]

Re: clutch dog issue(maybe?)

Does it have a noticeable "click" into gear when you shift it? If it does, you probably have a worn out dog and gear.. But if no click, check for a linkage or motor mounts problem.

 

[jpatterson12]

Re: clutch dog issue(maybe?)

No, no noticable click or other noise. I've had my suspicions about that linkage from the start. It doesn't look to me as if the lower rod is fitting into the linkage properly. I can still see a bit of the "neck" of the rod end sticking out of the brass linkage. I have the gear case in forward, and the gear shifter in reverse to maximise the "mating" of the two parts. Thank you both for your speedy replies. A couple of years ago, I bought a 6 hp Seahorse, and through the pages of this forum, I got that little outboard running like a top. All your help and advice is much appreciated.
Jon

 

[jpatterson12]

Re: clutch dog issue(maybe?)

Alrighty then. I finally opened up the gear case. I noticed the gear oil was milky, and figures if it needs seals anyway... I took a look at the gears and the clutch dog. The gears look crisp and sharp with no wear. The clutch dog showed a tiny, and I do mean tiny bit of wear on one ear, the other end looked perfect. It looks as though it was made the same on both ends, so I flipped it over before I put it back on the prop shaft. If my theory is correct, and the dog IS the problem, I'm thinking the worst is that I'll have a crappy reverse gear, but forward gear should work. Although judging from the looks of the inside of the gear case, the problem lies with the linkage. Keep yer fingers crossed, and thanks for the help.