Whaler Central - Boston Whaler Boat Information and Photos

Posted by Jdonohuejr on 04/01/12 - 3:52 PM

I'm working on replacing the water pump on the above engine and having a tough time getting the lower unit off. First of all, the service manual I bought seems to dance around this specific year, so it's not 100% clear what do do. However, it seems liike I need to remove the gear linkage underneath the carborators. This seems terribly unfriendly, but it seems to be the only thing holding up the complete removal. Also, it seems like it would be very difficult to reattach the linkage.

Does anyone have any experience with this vintage of Johnson and any tricks they can share?

Posted by Gamalot on 04/01/12 - 4:21 PM

I did the job on my 1984 Evinrude and I think it is about the same motor. Yes, the linkage is a PITA working so tight under the carbs and I removed them to be able to get in and do it, had to rebuild them any way.

There is also a very well hidden bolt at the bottom I did not find easily because the exhaust soot had it well covered. The side ones were easy but I think there is two bolts underneath that have to come out and the one under the trim tab is the one I never saw.

Posted by Jdonohuejr on 04/01/12 - 5:16 PM

Thanks, definitely a PITA! I thought the linkage was press fit but on closer inspection, it looks like it is screwed together and it looks like there is no way around taking the carbs off to get to it....prob rebuild them in the process. More work than I needed to do, but I guess I might as well.

Posted by cmeichler33 on 04/01/12 - 6:37 PM

I had an older Johnson and I did my water pump, and to get to that linkage I had to remove the starter. Hope this helps.

Posted by contender250 on 04/01/12 - 6:42 PM

There should only be one screw you need to remove from under the carbs to disconnect the shift linkage. You will need a long 1/4 drive extension with a swivel on the socket. there are 2 bolts on each side of the lower unit (4 total) and two hidden under the steering trim skeg (you will need to remove the skeg to get to one of the bolts) so you should have 6 bolts (plus one holding the skeg in place) and the screw for the shift linkage. The lower unit should drop down after this, however depending how long its been since being off and the amount of corrosion on the drive spline will give you a hard time.

Posted by Derwd24 on 04/01/12 - 9:36 PM

Second all that Contender says above. The shift link bolt is only threaded for about 1/2" on the shaft directly under the bolt head, the rest of the shaft is smooth and there's even a bit of a point at the end to make reinsertion easier. It's a pita to deal with, but no need to remove the carbs.