Johnson 3.5 outboard gear not engaged when moving the lever

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cmedsailor

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As mentioned in the title i move the lever to forward and no gear is engaged. Before that the lever was too stiff. I don't know if something was broken. I must dissaseble the lever but cannot figure out how. Any help please? Any diagram showing how is done? I could 't find anything on the internet for this specific thing. Thanks
Engine is year 2005, 2 stroke (those white ones)
 
I can't help specifically with your Johnson (no laughing at the back!) but when I had the same problem on my Tohatsu it was because the link rod had slipped, down at the gearbox end. Just had to tighten the clamp. It was a few years ago so I might be mis-remembering things a bit.
 
The lever only moves a rod which engages the gear at the bottom of the leg so might be easier to split the leg as if you were changing the impeller and see if it's moving as it should at that end.
 
cmedsailor said:
As mentioned in the title i move the lever to forward and no gear is engaged. Before that the lever was too stiff. I don't know if something was broken. I must dissaseble the lever but cannot figure out how. Any help please? Any diagram showing how is done? I could 't find anything on the internet for this specific thing. Thanks
Engine is year 2005, 2 stroke (those white ones)
Click to expand...

You don't state the model number , but assuming it's J3RSOD
The shift lever operates a vertical shift rod, via a bell crank, which engages with a spring clutch in the gearbox.

These diagrams show the arrangement

convert

convert


In the fist #16 and #20 are the shift lever and bell crank while #20 and # 19 are the shift rod and spring clutch in the second.

It seems most likely to me that if the shift lever was stiff you have forced it and broken its shaft ( instead rectifying the stiffness)

You will have to separate the power head from the leg replace the shift lever if that is so.


Full parts lists to which the above diagrams relate can be found at http://epc.brp.com/SiteMods/BRP_Public/BRP_Public_Login.aspx?ReturnUrl=/Index.aspx
 
Last edited:
Asking for help on an old thread.
My gear lever has failed. I have found the part number (0451585 )but can't find a supplier even on the net. Any one able to help
Vic S do you know if I pull the rod up will the engine stay in gear ? If so I will just keep it in gear.
 
surfernan said:
Asking for help on an old thread.
My gear lever has failed. I have found the part number (0451585 )but can't find a supplier even on the net. Any one able to help
Vic S do you know if I pull the rod up will the engine stay in gear ? If so I will just keep it in gear.
Click to expand...
0451585 is no longer available.

The detent system appears to be part of the shift lever mechanism so the clutch probably wont stay engaged unless you can jam the shift rod in the drive position .

the other possibility, I think, might be to remove the shift rod and seal off where it enters the gear case.

I've asked for ideas on the Marine Engine forums
Johnson 3.5, (ca 2004) broken shift handle
 
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