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Old 13-10-2016, 13:15   #1
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Johnson 3.5hp outboard problem

My 2005 Johnson 3.5 hp outboard has a very hard to move gear lever and I am hoping to take the outboard apart and see what ails it. It appears that I can detach the bottom part of the outboard from the powerhead by removing six bolts. My question is can I then just pull the bottom part of the outboard off? The manual I have does not seem to show how the powerhead is connected internally to the rest of the outboard. I don't understand how the powerhead is connected to the gearbox. This is a one gear (no reverse) outboard.

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Old 13-10-2016, 17:19   #2
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Re: Johnson 3.5hp outboard problem

When I was a kid I took an outboard apart. Be careful as I remember a lot of springs, tiny pins, thin gaskets. It was not easy to put back together.
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Old 13-10-2016, 18:40   #3
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Location: SF Bay Area (Boat in La Paz)
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Re: Johnson 3.5hp outboard problem

In addition to the bolts, there will be a coolant line and the gearshift tie rod still connected. Usually, the coolant line is a slip fit and will come apart on its own. The gearshift tie rod is likely bolted together. There may be a rubber plug part way down the lower unit. Remove this and you will find the clamping screws you need to loosen. The drive shaft will detach as you pull the units apart.

Also, you might get a gasket set, as the lower unit provides some of the coolant channels to the power unit, and they do need to be properly sealed on reassembly.
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