1986 DT 65 shift issues- please help

[brokb]

i have a 1986 DT 65, I had it at a marina a few years ago for some routine maintenance, it appears they rushed the job- when i got it back the shift controls were not hooked up on the engine side- i reattached them, boat drives fine, in forward..... The problem is the marina is 1.5hours away (only Suzuki dealer close at time)...i've gone for a year or two with out reverse.
Its driving me nuts, I've tried everything i can to get the reverse to go, adjusted the cables (engine side) and read forums, schematics...etc. I cannot seem to figure it out. I can engage it manually by pushing it into reverse, but the throw is somewhat off? I thought i had it the other day- ran great in reverse on muffs, but in the lake with prop under pressure, it didnt move. Not sure what to do at this point. any help would be appreciated.

where do i start?

also, when i put it in "neutral" at the shifter (controls) the clutch cable wont line up with the clutch arm control unless i unscrew (loosen) the clutch connector link until its all most completely unscrewed...even then when its in 'neutral' the boat wants to lurch forward like its still in gear. (it is). arg.....i hope this is enough information...if not please let me know.

 

[99yam40]

what kind of work did they do on the motor when this happened?
Did you call them when you found the problem to ask them what they could have done wrong?

Is this a turn style of shifter linkage to the lower unit ?
or is it a lift and push down type?

I know very little about Suzukis, but some of the Yamahas are spring loaded into forward.
so if you miss align the shift shaft it would do something close to what you are saying

 

[brokb]

It wouldn't stay running, had a bad sensor that they repaired.

For the motor to engage in gear, a bolt turns lifting the clutch up for neutral, down for forward, and up past neutral for reverse. Reverse throw (turns) is towards the back of the motor, forward is "forward" which pushed the clutch down.

 

[brokb]

"Pushes"^

 

[99yam40]

if no one has taken the lower unit off or apart, then I am at a loss as to what has caused this

might be something wrong with the linkage or something inside the lower unit

 

[mphelle8vld]

There are no sensors on that motor that would require disturbing the shift linkage so who knows what the shop was up to. If you need more adjustment to engage reverse, remove the cover on the back of your shift control box and adjust the cable from that end.

 

[mphelle8vld]

Wanted to add that while it seems you have exhausted all engine side adjustments, the clip that secures the throttle and shift cables allows for a lot of adjustment. Loosen the two 10mm bolts and the clip moves back and forth in grooves cast into the pan. Do this with the throttle cable disconnected, it will need to be re-adjusted after you get the shift linkage correct.