Re: thunderbolt 500 leg
fuzzy;
Here is the parts list for your s/n:
http://www.crowleymarine.com/mercury-outboard/437.cfm
Just to be sure that we are on the same page, what are you referring to when you talk about the leg? Is it the DRIVE SHAFT HOUSING ASSEMBLY
or the GEAR HOUSING ASSEMBLY, COMPLETE (PAGE 1)
It sounds like it could be one of two things:
1. The Lower Unit (Gear Housing Assy) has been installed without being in the same gear as the boat, or
2. Wrong position of the the reverse cam when positioned on the lower unit shift shaft splines
It might be best to drop the lower unit again and determine what gear you have it in or just disconnect the shift cable and ensure that the gears shift properly by hand Using the prop or prop shaft it will be in:
FORWARD if you cannot turn the prop CW
NEUTRAL if the prop turns freely in either direction
REVERSE if the prop cannot turn CCW
If you do it by disconnecting the shift cable, ensure that the lower unit can shift through all gears and then ensure it is in F or N by manually shifting it and then set the boat control to the same position and reconnect the cable and see if everything works OK.
If it is a problem with the reverse lock cam, you are going to have to drop the lower unit and make sure the cam is positioned correctly and that the guide is installed above it, items 45 and 46 here:
GEAR HOUSING ASSEMBLY, COMPLETE (PAGE 1)
Let us know if this helps
Here is a condensed version of the Clymer manual which may help you. Let the page load for 30/40 seconds as it is 5.3mb
http://web.ebscohost.com/serrc/pdf?...9073-ac6bbc485c10@sessionmgr104&vid=4&hid=123
Gerry
