Mercury 5hp 2 stroke - aligning drive shaft HELP

[andyorr]

Inherited a 1990's Merc 5hp 2str. Giving a thorough service. Now cannot get drive shaft realigned to mate inro engine. Main leg still on. Got prop/gearbox end off now ca't get it back on. Any hints and tips?

 

[NickiCrutchfield]

I've got a similar age 4.5hp and all I can say is it is a right bugger to put back together. Sometimes just knowing that a job is a nightmare for anyone is a help. On a more practical note though if you take out the plug, and 'feeling' your way up with the drive shaft very gently you can turn to engine slightly to mate with the drive shaft splines. What often happens is that it all goes home and you only have forward or reverse or both and no neutral..... It's horrid. I've found the easiest way to get it right is to be very very gentle, like using a key in a worn lock, and suddenly, bingo, in it slides.
I hope this helps a little.
Cheers,
Nicki

 

[NickiCrutchfield]

I forgot to say, don't forget to connect the water water inlet with the pipe in the leg.
Nicki

 

[VicS]

Nicki Crutchfield is right, turn the engine a bit as you try pushing the drive shaft in. Don't push so hard the the drive shaft turns as well though. Suddenly it'll go in.
Make sure the end of the shaft is clean free of burs and greased a bit. Very recently another forumite found that filing a very slight lead on the splines helped!

 

[FAITIRA]

Just changed the imp in my Tohatsu.
I had the same prob, I dressed the spline on the shaft, (includind the champhered lead) gently with a needle file, greased it and it went on first time, I had previously fecked around for 2hrs! Bill.

 

[FAITIRA]

[ QUOTE ]

Make sure the end of the shaft is clean free of burs and greased a bit. Very recently another forumite found that filing a very slight lead on the splines helped!

[/ QUOTE ]

Sorry Vic, didn't see you'r post, guess that was me? Bill.