Broken Shift Lever on 6 hp Johnson

[imccary]

Due to an unfortunate incident I have a broken shift lever on a 6 hp Johnson 6R79E(). The motor runs flawlessly and I won't part with it. Repair shop says the repair costs more than the motor is worth.

I am able to shift it easily with a vice pliers or pliars so in a pinch I have operated it that way. Does anyone have advice on the repair? Is it really as complicated as they are telling me?

I appreciate any advice. For now the trout are still in peril due to the vice grips but I would prefer a more permanent repair.

Thanks!

 

[Seasport]

Re: Broken Shift Lever on 6 hp Johnson

You certainly wouldn't be the first one to do this! You can replace the lever of course but you need to remove the powerhead to get it off and on. No big deal with these small motors - just takes a little time and care.

Have you got the bit that broke off? When this happened to my 6HP, I made up a couple of small stainless plates and drilled and screwed these to each side of the lever to hold the two parts together. Looks a bit ugly but does the job. I did try getting it welded but there's not really enough metal there for this to work.

I seem to remember a few others on iboats coming up with ingenious solutions but can't remember the details.

 

[imccary]

Re: Broken Shift Lever on 6 hp Johnson

You certainly wouldn't be the first one to do this! You can replace the lever of course but you need to remove the powerhead to get it off and on. No big deal with these small motors - just takes a little time and care.

Have you got the bit that broke off? When this happened to my 6HP, I made up a couple of small stainless plates and drilled and screwed these to each side of the lever to hold the two parts together. Looks a bit ugly but does the job. I did try getting it welded but there's not really enough metal there for this to work.

I seem to remember a few others on iboats coming up with ingenious solutions but can't remember the details.

 

[imccary]

Re: Broken Shift Lever on 6 hp Johnson

I dont' have the part that broke off, but I looked at the motor and I think I have enough of the shifter left to use your idea of the small stainless steel plates and I probably can fabricate some type of lever to make a safer, more permanent fix.

Thanks for the idea!

 

[Joey One]

Re: Broken Shift Lever on 6 hp Johnson

Here's how I did it. Get a fairly rust-proof screwdriver with about 1/4" shaft. Drill 17/64" hole thru the remains of the old handle and shaft at about a 20 degree angle from the vertical so the
screwdriver handle will clear the motor case. Then epoxy the screwdriver to the old shaft and handle.
I left mine about 6" long so I could shift while sitting on the starboard side

 

[Seasport]

Re: Broken Shift Lever on 6 hp Johnson

OK. Good luck!

 

[Seasport]

Re: Broken Shift Lever on 6 hp Johnson

OK. Good luck!

 

[Putzaroni1]

Re: Broken Shift Lever on 6 hp Johnson

I would love to see a picture or 2 of this repair. I have all the pieces but don't want to pull anything apart if I don't have to. Do any of you have any pictures ? The plates on the sides sound like a great way to resolve this.
Thanks.....

 

[geoffwga1]

Re: Broken Shift Lever on 6 hp Johnson

I respectfully suggest that you do it properly and get a new shift lever assembly.You don't say what your model# is but if Iboats doesn't have the part I'm sure Sea way marine does,they had one for my 61 5.5.Getting the power head off is easy,while it's off check your impeller too.Good luck.
Geoff69a1

 

[racerone]

Re: Broken Shift Lever on 6 hp Johnson

Those levers are a bit spendy $$$------------Use some fibreglass / epoxy and you can make a sturdy repair.

 

[Vic.S]

Re: Broken Shift Lever on 6 hp Johnson

I respectfully suggest that you do it properly and get a new shift lever assembly.You don't say what your model# is but if Iboats doesn't have the part I'm sure Sea way marine does,they had one for my 61 5.5.Getting the power head off is easy,while it's off check your impeller too.Good luck.
Geoff69a1

The OP says its 6R79E

The shift lever appears to be available for $107 . Part no 0389625

 

[racerone]

Re: Broken Shift Lever on 6 hp Johnson

I would want the whole motor for $107 ------I picked up 2 complete motors with good shift levers at $75 each.

 

[kbait]

Re: Broken Shift Lever on 6 hp Johnson

Top secret files.. salvage yards. Tim's outboard is one of 'em on the list. They'll have a good/used handle for cheap... and quick ship. 218-682-2331

Good luck!

 

[boobie]

Re: Broken Shift Lever on 6 hp Johnson

Also check the top secret files at the beginning of this forum for salvage yards.

 

[nwcove]

Re: Broken Shift Lever on 6 hp Johnson

maybe start a new thread, this ones almost 8 years old.

 

[boobie]

Re: Broken Shift Lever on 6 hp Johnson

Good catch Nwcove..............