Shifting in and our of gear

[AATA]

I have a 1990 200hp Johnson and when I go from forward to neutral it doesn't always come out of gear. If I pull back harder on the throttle arm (while not pulling in the shift lever) it will pop out of gear. I almost have to jerk it back. When I watch the linkage on the engine, it seems like the bottom cable/linkage (where the 2 adjustment dials are) has a lot of play and isn't being pushed enough. I can see when I go from forward to neutral it stops and if I pull back it pushes the linkage about 1 inch more and it comes out of gear. I'm hesitant to mess with anything so I don't screw it up even more since it's a brand new lower unit.

Here's a short history that may shed some light on the subject. I changed my lower unit with a brand new unit but the mechanic at my lake said some have straight cut gears and some have diagnal cut gears. I believe mine has straight cut which he said don't come out of gear as easy. He said it's normally not a problem, but mine is missing a throttle cut (I believe that's what he said) which relieves pressure so it can come out of gear. If I go quick from forward to neutral it usually comes out good or at least easier.

Is there an adjustment that would push that bottom link out more. The dials only seem to adjust pull since it slides out when it's pushing the linkage.

Any help would be greatly appreciated. I'm mechanically inclined, but I've heard I can really mess up the shifting if I play with the linkage and don't know what I'm doing.

Thank you!

 

[MRneatfreak]

Re: Shifting in and our of gear

It sounds like to me you have a cable/linkage problem, despite getting a new lower unit. On my boat the cables are way too long and there is about 5 feet extra dangling below deck before it goes to the engine. I have had the same problems as you before, and what ends up happening is the cable isn't being held in place tight enough at the carb hold down on the side. So when you move the shifter lever, the cable sheath is actually moving on the outside when it shouldn't be. Only the inner part should move, and the outer sheath should be locked into the recess by the hold down bar and screw at the choke plate.

Not real familiar with a 200hp. But on mine there is an arrow on the shifter linkage on the engine that shows where the linkage should be at idle/start up. That way you can line up your linkage on the engine, your cables, and your remote box shifter position and tighten it all down after you play around with the adjustment dials on your cables.

If everything looks tight at the choke plate where the cables are held down, start with small adjustments on the cable wheels and pay attention to which direction you turn them, as you may have to undue your previous adjustment.

 

[MRneatfreak]

Re: Shifting in and our of gear

Also be aware that if you go too far one way, it may not go into reverse or forward the other way, or it may start in gear even though the shifter is in neutral. So go through the ranges of motion on the remote box with the engine off after you make adjustments and make sure the prop is locked in both forward and reverse, and is free wheeling in neutral before you start it up, and everybody is clear of the prop.

 

[Chris1956]

Re: Shifting in and our of gear

Some of those motors have a shift assist switch which kills the spark to 1/2 the motor to make shifting easier. You should look at yours to determine if you have the switch and if it is working. Posting the model number can also tell us if you have that feature. The newer motors certainely have it. I am not sure about your motor. In all cases, get a service manual for your motor (OEM is best) and adjust the shift cable and shift rod height properly.

 

[AATA]

Re: Shifting in and our of gear

Yes, mine is supposed to have the shift assist switch, but it shifted fine until I put the new lower unit, which the mechanic said has straight cut gears that don't disengage as easy. Is the shift assist mandatory if my engine is supposed to have it?

MRneat - What you are discribing is what I feel it's doing. I will see if I can tighten the cables and take some of the paly out.

I have manual, so I will try to adjust them according to the manual. I've just been hesitant to mess with it, so I don't screw it up more.
Thank you!