Johnson 1966 4hp Manual
. 1168 Answers SOURCE: Hello Adam. If your propeller is OK, your lower unit will need some repair. It may be as simple as a clutch dog worn and not engaging the gear.
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Usually they give warnings of problems by jumping out of gear though. Other possibilities are broken driveshaft, propshaft, or gears. If it goes into reverse the shafts are OK and the clutch and forward gear become suspect. It was common for these engines to break at the top of the driveshaft where they were tapered.This would give you no motion at all and no previous warning of a problem. Check the gear lube for metal particles and signs of water intrusion. I hope your repair is an easy one.
KL Posted on Dec 08, 2009. What year model?
Tools you will need. (1)gear case pressure tester from any outboard dealer. Why buy and not build. Matching the threads on the drain plugs.(1) detergent and water in a spray bottle. Troubleshooting step (1) Remove lower unit from engine as if you were changing the impeller.(2) secure lower unit in a holder so you can drain oil and do visual checks.(3)remove drain plug and vent plug, drain oil(4) reinstall lower drain plug and put pressure tester into vent plug hole(5) pressurize gear case(6)with spray bottle spray gear case at all seals and joints just like you would spray a tire looking for a leak.
Detergent will bubble at leak.(7) if you find leak at a seal were you will need to remove drive shaft or propeller shaft you will have to buy removal tools and a Clymer repair manuel from your local dealer.(8) hopefully the leak is at the shift shaft or the drain and vent plugs so you wont have to buy special tools to replace seals.(9)if you find a crack in the case have it welded at you local outboard dealer Nov 03, 2009. I would think that the problem is a worn clutch dog. Drain the gear oil from lower unit. You need to disconnect the shift linkage and pull the lower unit like you would to change the water pump.
Then remove waterpump housing and waterpump base. The base will have a seal so you need to be careful and gently and evenly pry the base up until it comes off. Next you need to remove the prop and depending on the year there is a ring screw around the prop shaft that needs removed. Also there is a phillips screw that needs to be removed near the lower gear oil drain plug. That screw holds the shift cradle in place. From here you should be able to slide the drive shaft up and out and the prop shaft should slide out. The clutch dog is the smaller piece in between the two gears that engages fwd and rev.
You really should have a mechanic do the work but if you get a book it will help you. Pay very close attention how it comes apart and make sure that you dont mix up the fwd gear with the rev. Aug 05, 2009. Here is a website where a manual for you outboard may be purchased. Outboard Marine went out of buisness in 2000 and thus no parts of origial manufacture are support is available. Therir are secondary markets. THe Lower case splits in half and their is a seal around the prop shiftm which is pressed in. The seal between the cases are cut o-rings which are placed and glued into place with gasket seal.
The water pump is located where the case splits a little bit higher. You must open the little port on the side and take out one of the screws to the connecting shift linkage to split the case.
Johnson 1966 4hp Manual Pdf
After splitting the case the drive shaft and water pickup tube(s) wil come out of the powwer head or the tubs may stick into the power head which is ok. Place the lower skag into a vice and remove the 4 or 5 screws to the water pump housing. Remove and replace impellor and impellor plate if available.
Briggs And Stratton 4hp Manual
Honda trx450r manual. If part(pieces) of the rubber impellor is missing flush out the tubes and the power head to remove them. When reinstalling the lower unit use a flash light to make sure that the tubes return to the proper place in the power head and the shift lever is resecured. If you need more assistance, just write back. I was an Outboard motor mechanic for five years about the time of your motor. Dec 23, 2008.