Re: Johnson 25 jumps out of gear

[frankr]

That motor has the ball detents clutch dog. That is intended to ensure that the dog fully engages with the gear. Yes. it is true that external factors such as being out of adjustment can prevent that from happening. Tell ya what—many people tear those things down and say they look fine, when in fact they aren’t. It takes surprisingly little wear on the dog ears and gear recess to make it jump out. And every time it does that and slams back in, the wear quickly increases.

Bottom line is unless you find gross mal-adjustment, you need to go back in for a more critical look.