Johnson 4HP Shift stuck in drive

[Seastar]

Hello All
I am trying to fine information concerning the shift on a 1999 Model J4RSSM. (4HP 2-stroke) The problem is that the shift is stuck in drive and I can not work out how the mechanics works from the diagrams I have found. I was expecting to find a small access port in the intermediate casing where I could check that the shift rod was still connected (not sure to what though!) Also the oil level plug is seized solid (currently soaking in penetrating fluid) (any tips on getting this to move!) Moving the shift lever I can hear the mechanism in the lower gearbox area moving but it doesn't feel like its moving more that the rod itself. Can anyone tell me how to access the area, is it a matter of dropping the lower gear box and or removing the power head as well?
Any guidance much appreciated
All the best
Neil

 

[VicS]

Hello All
I am trying to fine information concerning the shift on a 1999 Model J4RSSM. (4HP 2-stroke) The problem is that the shift is stuck in drive and I can not work out how the mechanics works from the diagrams I have found. I was expecting to find a small access port in the intermediate casing where I could check that the shift rod was still connected (not sure to what though!) Also the oil level plug is seized solid (currently soaking in penetrating fluid) (any tips on getting this to move!) Moving the shift lever I can hear the mechanism in the lower gearbox area moving but it doesn't feel like its moving more that the rod itself. Can anyone tell me how to access the area, is it a matter of dropping the lower gear box and or removing the power head as well?
Any guidance much appreciated
All the best
Neil

Actually a 2000 model (SS are the date letters for year 2000) but probably no differences

Good diagrams on the BRP parts website http://epc.brp.com/Index.aspx?lang=E&s1=5d08437d-addf-4091-b31b-61594d2c426f

and at http://www.boats.net/parts/search/BRP/JOHNSON/2000/J4RSSM/parts.html

Some photos on Lakesailors server here http://www.lakelandimages.co.uk/Forum pics/info_engine/Evinrude4hp/

The shift rod is one piece and simply engages with the end of the clutch spring shown in the picture called "gearspring.jpg". It moves no other parts in the gear case.

Use an impact driver with a neatly fitting blade to undo the drain and level screws ( use new seals on them when refitting)

I think you will probably be able to tackle this without removing the gear case , but you might as well remove it, service the water pump and replace the drive shaft seal.

I guess you are going to find that the gear is seized to the propshaft. Perhaps all a sorry state inside if water has entered and the oil not changed

Fit all new seals when you rebuild it

The pictures on LS's website show how the water ways were blocked. Anything similar and you may have to remove the power head too.

Oakley Marine, aka Outboards-direct, in Brighton is a good source of spares http://www.outboards-direct.co.uk/


Dont forget to post photos of what you find

 

[Seastar]

Hello VicS
Many thanks for the information, I share your concerns that water has entered the area, I can recall that the fill screw corroded so badly a few years ago the oil has only been serviced via the level port, now the level plug is seized in as well. Will attach with impact driver at the weekend and see how it goes.
Looking at the diagrams from your links (thanks) I see that the clutch spring is on the prop drive shaft, does this mean that its the bevel gear on this shaft that moves horizontally in and out of engagement, I had expected to find it was the vertical bevel?
Thanks again for for your help, happy sailing
Neil

 

[VicS]

Hello VicS
Many thanks for the information, I share your concerns that water has entered the area, I can recall that the fill screw corroded so badly a few years ago the oil has only been serviced via the level port, now the level plug is seized in as well. Will attach with impact driver at the weekend and see how it goes.
Looking at the diagrams from your links (thanks) I see that the clutch spring is on the prop drive shaft, does this mean that its the bevel gear on this shaft that moves horizontally in and out of engagement, I had expected to find it was the vertical bevel?
Thanks again for for your help, happy sailing
Neil

Ive not had one of these apart but pretty sure that the gear and pinion will be in constant mesh. I think the spring simply acts as a clutch. I remember Lakesailor was a bit puzzled when he fist looked at it.

 

[Lakesailor]

I still am......

but I put it back together and it worked!