Broken gear shift lever

[spurg]

First time poster, long term lurker. thank you to everyone on this board.<br /><br />My problem: when i UPSed my 1978 Johnson 6 , the metal shift lever (arm) was broken at the elbow.<br /><br />A new lever is listed at 64$ so I am eager to find a way to reapir this one.<br /><br />I have searched the site, but have not seen this issue addresed. If it has been covered, please point me in the direction...<br /><br />otherwise, has anyone welded, glued, added a splint -- or in any way fixed a broken gear shift lever arm?

 

[DHPMARINE]

Re: Broken gear shift lever

That is pricey,and I believe you have to pull the powerhead to replace it.Thru the years I have replaced several handles that have been jury-rigged and failed,but I would give it a shot because of the price.Remember to shift ONLY when the motor is running.(lees strain on the handle).<br /><br />DHP

 

[rodbolt]

Re: Broken gear shift lever

only sure cure for it I ever found was replacing the handle<br />and yes powerhead removal is required

 

[spurg]

Re: Broken gear shift lever

That is bad news, i don;t want to remove the powerhead.<br /><br />I have been getting by with an adjustable wrench as an replacement for the broken arm. What if that wrench is welded on permanently?

 

[rodbolt]

Re: Broken gear shift lever

if you can weld an aluminium handle on it without melting the busing its ok I guess. I ran one with a pair of vice grips for 6 or 7 years.<br /> got it for 20 dollars because of the broke shift handle. sold it for 250 and it still had the vice grips on it. but by that time I dont think the vice grips would move again

 

[spurg]

Re: Broken gear shift lever

rodbolt - i do have the aluminum piece that broke off (about 50/50). Is it hard to weld aluminum? I am near Stamford, CT and I know there are plenty of welders around. I am not removing the powerhead. But if there is a high probability of the weld failing -- i think i am going to go with the vice grips fix. Did yours rust on after a few years of use?

 

[rodbolt]

Re: Broken gear shift lever

yep they did<br /> if you attempt the weld be aware that there is a nylon bushing on the shaft. tell the welder so he can set up heat sinks.

 

[itstippy]

Re: Broken gear shift lever

I don't know how yours is broken, but I've run a 20HP for some time now with the handle fixed with a piece of aluminum bar stock and an aluminum bolt. Don't know about the nut. It was this way when I bought the motor.<br /> <br /> <br />Click on thumbnail for bigger pic. Might've been a lucky break. I bought another shift handle on eBay but haven't put it on yet. I've got a small vicegrips in my boating "possibles bag" just in case, though!

 

[spurg]

Re: Broken gear shift lever

istippy - thanks for the pics - i think i will attempt this...

 

[Chinewalker]

Re: Broken gear shift lever

Why don't you want to remove the powerhead? There isn't anything that's going to jump out and bite you. Might have to replace the base gasket, that's about it. Seven or eight bolts and off it comes. The handle itself is only held in place with one bolt attaching it to the upper shift rod. If you can find a good welder, have him weld the handle back together with a neatly applied splint to strengthen the joint.<br /><br />It would also be a good time to replace the waterpump impeller, unless you are sure it has been replaced within the last couple years.<br /><br />- Scott

 

[itstippy]

Re: Broken gear shift lever

Pulling the powerhead and fixing the handle properly is apparently the only real longterm solution. $64 is pricey; keep an eye on eBay for the part. It'll turn up for $10-$20 depending on time of year and if anyone else needs one. Then you can do it up right. I'll be doing mine this winter. If either DHPMARINE, Rodbolt, or Chinewalker say you should do something, then you should do it. In this case all three recommend it.

 

[Seasport]

Re: Broken gear shift lever

Had exactly the same problem with my 6HP. Tried MIG welding it but it didn't hold - not enough material to weld. I ended up making a couple of stainless plates (I'm sure aluminium would be fine) shaped to fit the lever and bolting these on each side. Still holding.

 

[phatmanmike]

Re: Broken gear shift lever

dude, take off the powerhead. do it right, the first time.<br /><br />its a small little tiny 6 hp powerhead no bigger than many lawnmowers. it weighs about 20 pounds. ive done it. its tiny. and simple.<br /><br />just be glad its not a 225 v6!<br /><br />get a move on, man, fishing time is a running out

 

[rodbolt]

Re: Broken gear shift lever

depending on age and saltwater use pulling the power head can be easier said than done. if it all comes apart its not a bad job at all. just depends on if you wish to repair it or not.

 

[spurg]

Re: Broken gear shift lever

rodbolt, seasport, itstippy - i am going to do it right. i have a small 2 horse i can use while i have it apart. you guys recommend pulling the powerhead and you guys have been around these outboards...one small question: where is the pee hole on this 1978 6? same as the 2 (above water level on the trailing edge)? I have the selco but it never talks about it. or i can't find the chapter.

 

[Seasport]

Re: Broken gear shift lever

I removed the powerhead on my 6HP for another reason (couldn't separate the gear case to get at the impeller). Real easy. Just had to replace the base gasket. Probably should have replaced that shift lever while I was at it!

 

[Seasport]

Re: Broken gear shift lever

Yep peehole is where you say it is.

 

[spurg]

Re: Broken gear shift lever

seasport - thanks for the help. i will post after i get the powerhead off...

 

[spurg]

Re: Broken gear shift lever

After taking it apart, it looks like the thermostat is fouled, clogged and salted up. Can I get by without a t-stat? I mean, do i really need to worry about the engine getting too cold? (I am operating in 65 degree water all the time...I know this should be a new thread but I didn't want to start one for suck a little question)

 

[wilde1j]

Re: Broken gear shift lever

It'll run too cold w/o the tstat ... it's there for a reason. Plugs will foul, lots of carbon buildup, etc.