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Recent content by nicklanigan

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    1977 115 HP - Shift assist correct operation out of the gear case

    Hi all. I currently have the shift assist unit out of the gear case and am interested in what the correct operation is meant to be outside of the boat. I understand how it works - oil pumped up through the lower shift rod, and external movement of the rod causes the opening the appropriate...
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    1977 115HP Bearing Carrier Removal...

    Hi all. I need to disassemble the gear case - and cannot get the bearing carrier out. Attempted so far: 1) Factory method of 2 long bolts into the carrier then using a puller - result was a stripped thread in the carrier on one bolt hole. 2) Putting two shackles through the carrier, and...
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    1977 115HP Trunnion Slipping

    Hi all. My boat struggled to get into gear last week - it appears that the trunnion is slipping - just want to confirm that this is not normal - shown at the start in the following video: https://youtu.be/IGhTcWHDqac I'm assuming there is not meant to be any play at all? My first thought was...
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    1977 115HP - Spanner size needed for pinion locknut

    Hi all, I know I need to pull apart my gearbox this winter (I'm in the southern hemisphere) as I've got some symptoms of problems in there - I understand I need a flex spanner to hold the pinion locknut whilst the driveshaft is turned. I have the required adapter to attach a breaker bar to the...
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    1977 115 HP - Coil Failure - Ongoing issue

    Hi all, In 2016 I had a power pack failure - the power pack was one of the original johnson ones - no idea how old it was, but it was pretty old. Up until then, I never had a coil failure - even though 3 out 4 had cracks that had been siliconed over. The new power pack is from CDI. To avoid a...
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    1977 115 Dies on WOT/Hard Acceleration at 3000rpm - sometimes

    Hi all, I've had a frustrating problem with this engine for a number of years and don't seem to be able to get it sorted. Symptoms - under hard acceleration from idle, or from low rpm, the engine will occasionally simply quit at about 3000 rpm. Revs drop very quickly, and it just stops. If...
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    1977 115HP Warm Restart Issue - flames out on acceleration

    Hi all, I've got the following symptoms: Motor starts and runs well from cold, no issues whatsoever. After working the motor hard - towing kids on biscuits/wakeboarding etc, if I turn the motor off, I end up with a problem when I restart it. The motor will restart no problem at all, and will...
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    1977 115HP Tilt/Trim motor replacement advice

    Hi all, My tilt/trim motor may have an intermittent fault (it could also be the switch/wiring etc), however given it is only intermittent it is somewhat challenging to diagnose. The workshop manual I have isn't particular helpful in terms of steps needs to replace the tilt/trim motor should...
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    1977 115HP 115TXL77S Thermostat Housing Correct Assembly

    Hi all, just want to check I have assembled the thermostat housing correctly - mine was in very very poor state upon removal with a number of the gaskets missing. My assembly appears to align to the parts diagram - my query is really about the "cork" gasket for the thermostat - do I have it in...
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    1977 115HP 115TXL77S Thermostat Replacement?

    Hi all, As part of a wider engine rebuild I've pulled apart the thermostat housing. Just wondering if I should proactively replace the thermostats given it is somewhat tricky to get the thermostat housing on and off? The thermostats have an unknown age - at least 8 years old, and only used...
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    1977 115HP 115TXL77S Water Tube Grommets

    Hi all. Pulled off the gearcase the other day to replace the impeller - first time I've personally done it. Just a question on the water tube grommets involved - according the parts diagrams there are two water tube grommets - one is located in water pump body, part #314008 from the following...
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    1977 115HP How does the cooling system work?

    Hi all, time for another of my queries regarding how these engines work... note I'm not trying to fix anything, but to increase my understanding. I'm trying to get my head around how the water system works - I've just completed a rebuilt of the power head, so have intimate knowledge of how...
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    Compression testing - confessions of a coil destroyer

    Just a note for anyone interested - make sure you ground out your plugs or use the kill circuit/ignition off etc when doing a compression test. Eating a slice of humble pie here - and I'm an electrical engineer - for years I did compression tests by simply pulling out the plugs, leaving...
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    What's inside a starter pinion gear assembly, and how exactly does it work?

    Hi all, I've had cause to do a bit of work on my starter motor as part of an overall rebuild, and have discovered a problem with my pinion gear on the starter. The replacement gear is on order, so all I'm looking for is some info on what is inside the pinion gear, and how it works. Like many, I...
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    1977 115HP Piston Ring Locating Pin Acceptable Length

    Hi all, Doing a rebuild of this engine, and have two pistons that have worn a locating pin completely away. A third piston has a pin that has been worn to approx 2.1mm long (0.083"). A new pin is probably 4.3mm long (0.169"). The workshop book I have states simply check for excessive wear...
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