1992 yamaha 2-Stroke 85hp tiller handle lower unit

[Dano3578]

If I remember correctly, when I first bought this motor(5years ago) it always made clicking noise while in neutral and I'd spin the prop by hand. While motor is off of course. Fast forward to last week. My cousin slammed it into reverse while it was idling kind of high. I tore the lower unit down and found that the dog clutch is worn and the pin that holds it on the shaft was bent. I have seals and new parts mentioned above on order. My question is can the bent pin cause the dog to ride ever so slightly on the drive gear causing the noise ?

 

[Dano3578]

I'm also wondering what else can cause the linkage to be off causing the noise ? I've been told to adjust the linkage near the power head but I run out of threads. When using the shift handle on tiller, the linkage is almost all the way in reverse before the noise stops while in neutral.

The splines on top and bottom of the shift rod look good. I ordered a new shift lobe though. It showed a little wear.

 

[99yam40]

someone trying to shift while motor is not running can cause the shift shaft to twist.
found that on my brothers old C60, along with the bent pin.

But maybe someone did not have everything in neutral when stabbing the lower unit in

 

[Dano3578]

I won’t know for sure until I get all my parts in and assemble them. At this point if my sync is still off it has to be the midsection linkage shaft

 

[99yam40]

here is a link to the post for my brothers C60,
but being on a different web site I am not sure it will work

C60 TLRY lower unit making some clicking noise in neutral while idleing - Yamaha Outboard Parts Forum

Ask the experts on our Yamaha Outboard Forum for repair issues, diagnosing problems, links to diagrams, suggestions on buying parts and more. They can answer questions for any Yamaha outboard model or horsepower.

www.yamahaoutboardparts.com

 

[99yam40]

here is a pic of the shift shaft that was twisted

 

[racerone]

I would remove lower unit.------Put lower unit in neutral.-----Put linkage on motor to NEUTRAL.-----Then re-assemble and adjust shift cable.-----Sounds like the splines between lower unit and upper shift rod have been out by one for a while.

 

[Dano3578]

here is a link to the post for my brothers C60,
but being on a different web site I am not sure it will work

C60 TLRY lower unit making some clicking noise in neutral while idleing - Yamaha Outboard Parts Forum

Ask the experts on our Yamaha Outboard Forum for repair issues, diagnosing problems, links to diagrams, suggestions on buying parts and more. They can answer questions for any Yamaha outboard model or horsepower.

www.yamahaoutboardparts.com

Thanks I’ll give it a read

My shift shaft doesn’t look near as bad as your brothers. Really appreciate you. As soon as I get my parts in I’ll update

 

[Dano3578]

I would remove lower unit.------Put lower unit in neutral.-----Put linkage on motor to NEUTRAL.-----Then re-assemble and adjust shift cable.-----Sounds like the splines between lower unit and upper shift rod have been out by one for a while.

I believe you may be on to something
Appreciate your input. I’ll update when I receive my parts

 

[Dano3578]

The 2-3 times I’ve changed the impeller over the years ….. the shift shaft just didn’t seem right when everything was in neutral up top and trying to get the lower unit in neutral. I’m really starting to believe it was the bent straight pin and the shift cam all this time. The incident with my cousin just topped it off. Thanks again guys