Tiller motor jumping out of gear

**Hanr3** · 10-20-2016, 10:55 PM

My 1995 40hp Evinrude jumps out of forward gear under light load. Under full load she stays in gear. All started one day while in Canada. I think we hit a Muskie at top speed, motor bumped up, heard a clunk, she popped out of gear, I powered down to idle, put it back in gear and opened it up to full throttle and we where on our way again. Lately though she pops out of gear under light load and it seems like the shift linkage is about as far as she will go. Used to engage sooner than it does now.

Shift linkage is the type that you spin the shift rod in or out to adjust shifting. I haven't touch the linkage. Maybe clutch dog?

What are your thoughts?
I'll be pulling the lower unit off this fall/winter to fix. Trying to get an idea of parts I will need before I get started.

**Cray** · 10-21-2016, 06:03 AM

First thing is check your shift rod for being bent. Lot of cases that is what happens when hitting something. Very slight bend can cause it to be to short to let it completely engage. From there would be forward clutch dog. I'm betting slightly bent shift rod.

**Hanr3** · 10-21-2016, 08:05 PM

Hoping its only a bent shift rod. That would be great. Not sure how it would bend, not exposed. If you could help me understand the mechanics of how it could bend that would help me tremendously.
Thanks!

**Cray** · 10-21-2016, 08:33 PM

Not knowing your motor that's a hard question to answer. Some are exposed somewhat. On yours I would think the shock load on the shift dog could possibly force it up just enough when you hit what ever you hit to put a slight bend in it. I would sure check every inch of linkage including the shift leaver position before tearing into lower unit.

**scrat** · 10-21-2016, 09:22 PM

I had a Evinrude motor that jumped out of gear some what like that and after replacing the clutch dog it work just fine.

**dfar** · 10-24-2016, 11:51 PM

Check the link that connects the shift rod to the shift arm under the carb to see if it is cracked/bent/or loose. That can also cause the symptoms that you are describing.

**sliderman** · 10-26-2016, 07:39 AM

A couple of questions.
You mentioned it doesn't seem to engage into forward gear as soon as it used to. Does it seem to engage into reverse sooner?
Have you inspected the linkage system under the cowling? There is a detent ball that holds the linkage in position. It's the first resistance you feel in the shifter. The ball is held in place by a spring and retention socket.

Although inspecting the connection point under the bottom carb is a good idea, those components are made of metal and should not be damaged. The same can be said of the shift shaft being bent. The most common issues I see are accidental adjustments of the shift shaft while servicing the water pump and failure of the detent ball mechanism. The shift shaft has a tendency to twist as the lower is being removed. One turn in the wrong direction to correct the alignment will result in a change in the contact area of the clutch dog ramps and their contact points with fwd and rev gear.
I would be inspecting the detent mechanism I mentioned earlier followed by removal of the lower unit and measuring the shift shaft.

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