See full version: How to Repair the Lower Shifter on a Mercury Outboard 90 HP
Coat the shift rod guide, three new O-rings and the shift rod seal from the shift rod kit with waterproof marine grease. Install the shift rod guide assembly in the shift rod housing, inside the engine's exhaust tunnel. Install the smallest washer and seal from the shift rod kit into the shift rod.
When the gear shift on a Mercury outboard engine begins to feel stiffer than normal, the engine may have a bent lower shift rod. If you need to repair the lower shifter on your Mercury outboard, you can purchase a kit with all of the parts required to make the repair. If you are a boater with extensive experience with outboard care and repair, this kit, some marine grease and a few tools will allow you to complete the project with little trouble.
Secure the shift rod spring and collar on the other end of the shift rod with the snap-ring from the kit, using snap-ring pliers. Line up the shift rod with the shift rod detent cam. The detent cam is an oblong plate with a spring and a ball at its center, located at the bottom of the shift rod housing. It creates the feeling of a "bump" as you pass between gears when operating the boat. The cam must face the rear of the gear case. Install the cam, using the pin from the shift rod kit.
Dab thread locker onto the shift rod cover bolt threads and the dowel pin of the shift rod cover. Push the dowel pin into place on the cover and install the cover on the gear case. Thread the bolts into the bores on the gear case by hand. Tighten them to 45 inch-pounds of torque with a torque driver.
"Dropping" the lower unit on a Suzuki outboard looks straightforward; you remove the nuts and give a strong pull straight down, so that you don't damage the drive and shift shafts. If you follow this prescription for removing the lower unit of a Suzuki outboard, you'll find yourself frustrated unless you remove the bolt hidden beneath the zinc anode and the trim tab that you have to remove. Once you remove the trim tab, the anode and the bolt, the process may continue apace.
Loosen the two forward lock nuts. Do not try to remove the other nut before the opposite side is loosened or the driveshaft housing could be damaged. Do not remove the lock nuts before you start to separate the lower unit from the rest of the motor. here
Place the lower unit in a suitable holding fixture or work area. [links]
Go here to find your manual, make sure it is applicable to your engine, model and serial number.
It will tell you how to correctly hook up your linkage.
Push down on the shift cam assembly to ensure the lower unit into reverse gear. Rotate the propeller counter clock wise if you have to to facilitate the lower unit shifting into reverse. Make sure the shift lever is in the full reverse position. here
Job done. It should all work correctly now. [links]
Hello All
I have a 2008 yamaha 2 stroke 25 hp outboard 25MSH 6L2K 1040491
I needed to change the water pump impeller, So I changed the impeller. here
When putting it back together I seem to have got the Shift adjustment out.
I originally had to remove the shift lock nut to remove rod coming down from tilt area. after putting this back my neutral is not specific its either rev or Forward and it starts in Gear . so now I got it all out anyone have a step by step how to get it all back in proper adjustment. I have NOT touched any linkage above that Linkage nut, the engine is a Tiller Steer model with shifter on front of the motor. [links]