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Yamaha 9.9 shift linkage in lower leg is acting like it's disconnected. Can't change gears or go to neutral. Removed leg to fix water intake and when I hooked it back up unable to shift. Removed lower leg again and linkage moves up and down but not disengaging.

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Make sure that throttle is all the way back to idle or it will not be allowed.

Posted on Oct 08, 2009

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1983 Johnson outboard . Model J25TECTE. Runs Forward/Reverse. Shift rod connection OK. Shift in neutral it runs in reverse. Do I need to change something in the gear case section?


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I need to disconnect the shift linkage of a 1983 Johnson outboard motor. I already disconnect at the water inlet. The lower unit still will not come all the way down.


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In the leg, undo the gear link and undo the bolts that hold the lower half of the leg on, they are above the water intake pointing up, don't forget the bolt neat the prop. Wiggle the leg off and put it on the bench. The drive shaft protrudes from the center of the water pump housing, remove the bolts and slide the housing off. When you replace the impeller make sure the fins are folded in the correct direction to avoid pinching. Be sure to align the water cooling pipes when reassembling the leg.

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1 Answer

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Put the motor in neutral.On the leg of the motor there is a little side cover plate.Remove.Undo the bolts.This is the gear change linkage.At the cavitation plate,there is 4 bolts.Remove.If the lower housing does not drop,give it a soft whack with a soft hammer.When dropped,you will see the prop shaft and the gear linkage.Lower it all the way out.Its easy to work on if you put the lower skeg in a vice.Take the water pump apart BUT!!! have a look at which way the impellar blades are pointed.Grease the new impellar as you put it back in and turn it at the same time to get the nodes in properly.Heaps of grease to protect all the bolts.Makes it easier next time.Hope this helps

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1 Answer

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I need year model to be precise? But here are the basic tools and troubleshooting steps. TOOL (1) a black marker.(2) a tape measure (3) a second person. TROUBLESHOOTING STEPS(1) the force need water so put it in the lake or install water hose.(2) do not start engine yet. remove engine cover and find shift cable by shifting remote control. once you find were the shift cable connects to the shift linkage. learn which way is forward and reverse. is it push or pull by the cable. remove the cable.(3) now the shift mechanism is removed from the boat controls. this test will require you shifting the shift linkage by hand so stay clear of the flywheel and all moving parts. (4) start engine. at idle speed and you in a safe location near the shift linkage shift engine into forward gear by the shift linkage. be aware how far you need to move the linkage before it shifts into forward. Mark that location with the maker somewhere you can see.(5) shift the linkage back to neutral. mark location were neutral begins. you will fill it click out of the forward gear.(6)now shift into reverse gear marking that location.(7) shift it to neutral making that location as you fill it leave the gear(8) shut off engine turn off water or take it out of lake (9) look at you marks and measure the distance between neutral and forward. the measure the distance between neutral and reverse(9) the second person needs to be in the boat to work the remote control. you need to be at the engine with the tape measure. person #2 needs to make sure remote control is in neutral. you need to measure the remote control cable end so you get a measurment with it in neutral. make a note of the neutral lenght.(10) person #2 shift remote control into forward gear. you measure cable end for distance traveled to go to forward.(11) make the measurement for reverse same way.(12) this is how you find out if you clutch dog is to wore out to stay in gear by the travel of the shift linkage compared to the travel of the shift cable. There are adjustments but they only go so far. that means you will have to sacrifice one gear for the other to make up for the distance of travel.

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1 Answer

We have a 9.5 johnson outboard motor, it works in neutral and reverse, but when we put it in gear, it immediately pops back into neutral. How do we disassemble and fix this problem?


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