Re: shift cable adjustment?
As others said it's extremely bad on the u joints to run the motor, even in neutral, with the drive all the way up. In fact they are probably shot if you have run it like that very much at all. I think they are only meant to be run a little more than a quarter of the way up. I think there is a specific measurment for the trim cylinders. If the boat shifts fine with the drive all the way down it mite be ok. Someone with more experiance than me could chime in on that though.
Here is what the service manual sais for adjusting the shift cable I was able to download it before they were taken down:
1. Push in on drive unit shift cable while simultaneously turning propeller shaft
counterclockwise until shaft stops. To ensure that clutch is fully engaged, maintain
pressure on propeller shaft with a suitable device (elastic strap).
2. While applying light inward pressure, rotate barrel on shift cable threads until distance
between center of hole in shift cable end guide and center of brass barrel measure 6 in.
(153 mm).
3. Remove remote control shift cable and shift assist assembly (if installed).
4. Shift remote control as stated in ?a? or ?b? following:
a. Right Hand (RH) Rotation Drive Unit - forward gear, past detent, into
wide-open-throttle position.
b. Left Hand (LH) Rotation Drive Unit - reverse gear, past detent, into
wide-open-throttle position.
5. Place drive unit into gear by pushing in on drive unit shift cable, while simultaneously
rotating propeller shaft counterclockwise until shaft stops, to ensure full clutch
engagement. Maintain a light pressure on the drive unit shift cable to hold it at the end
of its travel (this removes all slack from the cable).
IMPORTANT: Do not use excessive force when holding pressure on the drive unit
shift cable. Excessive force would be indicated by movement of the v-notch on the
shift cutout switch.
6. Lightly pull on remote control shift cable end guide (to remove slack from remote control
and cable) and adjust brass barrel as necessary to align attaching points with shift lever
clevis pin hole and stud. Be sure to maintain light pressure on drive unit shift cable.
7. After cable has been aligned, turn brass barrel 4 turns away from cable end guide.
8. Temporarily install remote control shift cable on stud and install clevis pin.
9. Shift remote control as stated in a or b following:
a. Right Hand (RH) Rotation Drive Unit - reverse gear, past detent, into
wide-open-throttle position.
b. Left Hand (LH) Rotation Drive Unit - forward gear, past detent, into
wide-open-throttle position.
10. Simultaneously rotate propeller shaft clockwise until shaft stops to ensure full clutch
engagement.
11. Perform a or b as appropriate:
a. On Models with Earlier Type Switch: check shift cutout switch lever position.
Roller must be centered.
b. On Models with Later Type Switch: check shift cutout switch plunger position. Pin
must be centered.
12. If roller or plunger pin is not centered:
a. Ensure adjustable stud is at bottom of slot in shift lever.
b. Check remote control for proper shift cable output [3 in. (76 mm) ? 1/8 in. (3 mm)].
Refer to ?Installation Requirements.?
c. If a and b are correct, ensure drive unit shift cable is not crushed or kinked. (If drive
unit shift cable is binding, the shift cutout switch roller or plunger pin will move off
center when shifting ?into? and ?out of? forward and reverse).
NOTE: If shift cable was damaged during installation, install new shift cable assembly in
accordance with instructions contained in sterndrive service manual, then repeat shift cable
adjustment procedure.
NOTE: Some controllers, such as the Commander 3000, have different adjustment procedures.
Refer to the appropriate installation instructions for the model being repaired..
13. After remote control shift cable has been properly adjusted, reinstall cable and shift
assist assembly (if applicable) and secure with hardware as shown. If shift assist
assembly attaching points will not align, push in or pull out on end of shift assist
assembly to install. Do not attempt to readjust shift cable.
.