Johnson 9.9 ... Throttle Gear Teeth Broken

[PaxRiver]

I have a 1984 Johnson 9.9 outboard with the twist grip tiller handle. When I twist the grip to adjust speed, the gear on the end of the twist grip shaft slips where it mates with the gear on the short shaft going into the engine compartment to control throttle likage. It turns out both the throttle shaft gear and the short shaft gear have broken teeth. It's not obvious how to remove & replace (or repair) the gear on the short shaft. I also can't tell whether any of the plastic gears/linkage are in good shape ... I can move these by manually moving the linkage & they seem to work properly. However, the slipping throttle gears prevents me from seeing how they operate when I twist the grip. I sure could use advise before I start attacking the motor. I'd also like advise on things to consider (e.g., alignments, things to inspect, etc) before I begin the work. I'd hate to have everything apart & not know how to properly put it back together. Thanks --- Jeff

[OBJ]

Hi Pax.....The gear that is attached to the motor is held in place by a snap ring on the back side. Swing the motor to port and look underneath where the gear is and you will see it. The shaft from the gear into the pan is square on the ends with "nubs" that align the shaft correctly to the gear inside the pan with the one you want to remove. One end has two nubs and the other ends has three.The tiller handle, remove the screw holding the twist grip hand on and the handle will slide off. Watch the spring while removing. Flip the handle back to expose the underside and you will see another snap ring near the gear. Remove this snap ring and the gear and shaft will slide out.Clear as mud???? LOL...Keep us posted.

[knobby]

Good reading on your problem, http://www.pugetsoundanglers.org/Fis...n%209.9_15.htm

[Bass Runner]

about as clear as i could have got it.

[BF]

Hiya,There's quite a bit of slop in those gears, you might be able to shim back the ones in the tiller arm enough for them to still be useable. (depends on how bad they are). After you get the gear & rod out of the tiller handle, slide a couple of nylon washers onto the rod and reinstall. That moves the gears back to a more solid mate with the ones on the linkage... adjust by using thicker/thinner washers.Oh, and there are some spots on those gears that don't have teeth (to make sure that they can only match up one way), so have a good look to see whether they really are broken. Mine were completely unuseable, but with shims are fine. Love those fixes that don't cost any $$$!Brent

[PaxRiver]

Thanks all. I'll look for the snap ring this weekend once it stops raining. I understand there is supposed to be an area without teeth on both gears, but there are now more flat areas than sections with teeth :-)I forgot to ask whether replacement gears (or shafts with gears) are easy to find (and cheap)

[OBJ]

Yea Pax....they are still available. Pricey but available. Shop around for a used set. May a local dealership will have them. Check the link below. http://www.twincityoutboards.com/ Keep us posted. Good Luck!