Gear shift problem

[mcurko]

Hallo,<br /><br />I've recently bought a Mariner 5 HP 2-stroke outboard motor. The following problem occurred to me a few times (4 to be precise, in a 2 months period): I turn on the engine, shift into reverse, back to neutral and then, when I try to shift into forward I cannot do so because of a mechanical resistance (as felt on the gear shifter). (Gear shifting is always done swiftly and at idle speed.) Since I absolutely had to shift into forward (otherwise my boat would be damaged in the harbor by hitting other boats) I forced the shifter (not happy to do so!) and managed to shift into forward. Once, the fourth time, I couldn't shift into forward even by forcing the shifter. Luckily the harbor was empty at the time and I managed to avoid a disaster in the harbor by approaching the dock in running in reverse. Then I turned off and on the engine and somehow managed to shift into forward. So, this problem occurs rarely but is still a serious one. In the meantime I changed the gear case oil (after 20 hours of use) and noticed that the oil that leaked out of the gear case was much brighter than the new oil I put into the gear case (which is more-or-less black). Now, I am not sure if the oil the manufacturer puts in the gear case before shipping the motor to the shop is supposed to be exactly the same oil used for periodic oil replacement, or should this "brighter" oil be regarded as a sign of a problem? After replacing this oil I haven't checked the state of the "new" oil (don’t like to mess with the motor more then necessary). Anyway, could it anyhow be related to my problem? Or what should I do? My motor is still under warranty but I am afraid that it might be uneasy for a technician to fix a problem difficult to reproduce! And if they tell me they fixed the problem, how do I check it by myself?!<br /><br />I'll be thankful for any help!

 

[andrewkafp]

Re: Gear shift problem

I assume the gear shifter is on the side of the motor (Tiller drive). What I think happened is when in reverse and neutral, there is a lock that prevents the motor from flipping out of the water. You may have tried to engage forward gear while the motor was still under load and locked, putting pressure on the shift shaft. The shift shaft will most likley have a clamp joining upper and lower segments and it may be out of adjustment. There should be a cap on the side of the leg that you can remove and inspect/adjust it. As for the oil... If there's no water in it, it will just be metal from the run in period. Change it and keep an eye on it.<br />Comp 9,10,11<br /><br />

 

[mcurko]

Re: Gear shift problem

I have inspected the motor and compared the actual assembly with this picture. I found a linkage between the gear shifter and the starter assembly which is, I believe, used to prevent starting the motor when not in neutral gear. I don't think this linkage could block the gear shifter.<br /><br />Additionally I discovered a particular "hook" mounted on the front side of the leg (here "front" means the side of the motor closer to the boat). Below this hook there is a vertical shaft that moves up when engaging the forward gear and down when engaging the reverse gear. When moving down in reverse gear it allows the hook to switch in a position in which it prevents the motor from flipping out of the water. This hook, however, does not seam to be able to block this shaft from moving up and down (in neutral gear the shaft does not allow the hook to block).<br /><br />I don't understand what does it mean "out of adjustment" when talking about the shift shaft? Aren't the shift shaft segments connected in a way that just propagates the rotational movement of the shaft directly to the lower drive unit?

 

[DHPMARINE]

Re: Gear shift problem

mcurko Not sure about European Mercs,but here goes......<br />There is a tube in your tiller arm that is stainless steel,and has a plastic 'cam' on each end.This connects the twist grip with the housing that contains the cables that actually shift the gearcase.<br />I think you'll find one of these 'cams' is not firmly bonded to the tube,and slips.It is erratic because the tube is knurled and doesn't always slip.<br /><br />DHP