Johnson 5 outboard gear shift issue

Myrddin

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2 May 2024
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Hi folks
Just gone to try out my outboard for the caprice, engine runs sweet, but she wouldn't shift into gear! So I have stripped the leg down and removed the gearbox. Bix was stiff but now selects, it's the shifter handle itself that has jammed.
So I took the leg off the engine removed the handle and the bar itself is seized.
Any ideas how to free it up? Tried WD40 and some gentle persuasion with a hammer and molegrips, not budging.
Trying vinegar next, then heat if that doesn't work. Is it just rubber grommet? Or bearings in there too?20240512_155307.jpg
Many thanks
 
You dont say what year ( or quote the model number, which will tell all) but almost certainly seized due to corrosion of the alloy casting gripping the shifter shaft
Heat will probably be the only way to release it unless prolonged soaking with an acid such as vinegar to dissolve the oxide is effective.
I think you will find there are two O rings in there

It looks like a 4 stroke model model from between 2003 and 2007 from what I can see which is really a Suzuki. If so the parts of the shifter are in the diagram attached.

1715543646077.png
 
You dont say what year ( or quote the model number, which will tell all) but almost certainly seized due to corrosion of the alloy casting gripping the shifter shaft
Heat will probably be the only way to release it unless prolonged soaking with an acid such as vinegar to dissolve the oxide is effective.
I think you will find there are two O rings in there

It looks like a 4 stroke model model from between 2003 and 2007 from what I can see which is really a Suzuki. If so the parts of the shifter are in the diagram attached.

View attachment 176872
Apologies , indeed that information would be helpful 🫣
20240512_212233.jpg
 
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