Broken gear selector - Mercury 3.5hp

[Tim Good]

Ok I recommission my 3.5hp mercury this morning which started on second pull!!!!

However.... the gear selector handle was really stiff so I forced it unfortunately and it seems to have sheared somewhere as now it is fairly loose but doesn't select forward gear.

1. What would make it so stiff to select forward?
2. What have I likely done? Just proven the handle and rod perhaps?
3. Anyone had a similar issue and know how easy it is to fix?

 

[steve66]

Ok I recommission my 3.5hp mercury this morning which started on second pull!!!!

However.... the gear selector handle was really stiff so I forced it unfortunately and it seems to have sheared somewhere as now it is fairly loose but doesn't select forward gear.

1. What would make it so stiff to select forward?
2. What have I likely done? Just proven the handle and rod perhaps?
3. Anyone had a similar issue and know how easy it is to fix?

The gear lever shaft usually seized inside The bushing. If so im guessing you have broken The handle. Not sure if you can just replace The handle. If Not its a powerhead off job

 

[Tim Good]

If Not its a powerhead off job

Yeah I thought that might be the case. Is it a total pain of a job? New gasket as well then I suppose?

 

[VicS]

Ok I recommission my 3.5hp mercury this morning which started on second pull!!!!

However.... the gear selector handle was really stiff so I forced it unfortunately and it seems to have sheared somewhere as now it is fairly loose but doesn't select forward gear.

1. What would make it so stiff to select forward?
2. What have I likely done? Just proven the handle and rod perhaps?
3. Anyone had a similar issue and know how easy it is to fix?

exploded diagrams here : http://www.boats.net/parts/search/Merc2/Mercury/parts.html may help

 

[jwilson]

If you'd sheared off the top lever on the powerhead it would probably be obvious - have you opened up the small rubber cover near the bottom of the drive leg to see if the clamp that joins the two sections of the gear selector rod has come undone? The other break point is the lever that transfers movement to the up-down rod: just under the powerhead, held in place by a grub screw if I remember rightly. On two-strokes fairly easily accessible: not sure about four-stroke versions.