Mercury O/B - stiff gear lever

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CJ13

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We've a Mercury 3.5- 4 stroke outboard (same as Tohatsu), bought new in Sept 2010.
Last autumn (2011) the gear lever became very stiff. It still worked but required a lot of effort. The stiffness occured suddenly, while the engine was in daily use.
The owners manual makes no mention of service/ lubrication of the gear lever. I've tried 3in1 oil which has made no difference.
A friend has a similar Tohatsu engine with the same problem.
Does anyone know the cause and fix?

Thanks,
John
 
JFowler said:
We've a Mercury 3.5- 4 stroke outboard (same as Tohatsu), bought new in Sept 2010.
Last autumn (2011) the gear lever became very stiff. It still worked but required a lot of effort. The stiffness occured suddenly, while the engine was in daily use.
The owners manual makes no mention of service/ lubrication of the gear lever. I've tried 3in1 oil which has made no difference.
A friend has a similar Tohatsu engine with the same problem.
Does anyone know the cause and fix?

Thanks,
John
Click to expand...

Remove shift lever clean lubricate and reassmble is the answer ... and before you break it.

Look at the possibility of fitting a gease nipple.
My Evinrude has a greasing point for the shift lever ... it's as free now as it was in when new in 1985.

Lakesailor will be along shortly with some more practical help
 
It's not obvious how to remove the gear lever - there's no fixing/ bolt visible. Any suggestions appreciated?

John
 
JFowler said:
It's not obvious how to remove the gear lever - there's no fixing/ bolt visible. Any suggestions appreciated?

John
Click to expand...
Small plate under the handle you pick the thing up with on ours. Two 8mm (10mm?) bolts. Then there's a screw that connects to the rod linkage which goes down inside the leg which you need to release before withdrawing the gear shift lever.

Sorry I can't help with the forum search, perhaps someone else will help?

The link above is to the four stroke, I am assuming yours is a two stroke and the gear linkage is here:

http://www.boats.net/parts/search/Merc/Mariner/1999/7003211HK/SHIFT LINKAGE(3.3 HP)/parts.html
 
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john_morris_uk said:
Small plate under the handle you pick the thing up with on ours. Two 8mm (10mm?) bolts. Then there's a screw that connects to the rod linkage which goes down inside the leg which you need to release before withdrawing the gear shift lever.

Sorry I can't help with the forum search, perhaps someone else will help?

The link above is to the four stroke, I am assuming yours is a two stroke and the gear linkage is here:

http://www.boats.net/parts/search/Merc/Mariner/1999/7003211HK/SHIFT LINKAGE(3.3 HP)/parts.html
Click to expand...


Read again the first line of the OP's post ... s l o w l y :D


I suspect the powerhead will have to come off the leg to access the linkage I have no idea what will be involved in doing that.
 
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Thanks all - i'll have a look tomorrow.
For the record ours is a 4 stroke and only 18 months old- i'm suprised that i've this problem with such a new engine.

John
 
If the lever is like the 2 stroke then there will be a panel to access where the gear lever joind the gearbox linkage. From memory there is a screw holding the gear lever to the linkage.

At this point the gear lever shaft won't pull out as it is still seized! Plenty of freeing agent light oil and patience plus lots of wiggling worked for me. Cleaned the shaft with fine emery cloth and regreased. No probs for ages (will have now I've posted this!)
 
rickym said:
If the lever is like the 2 stroke then there will be a panel to access where the gear lever joind the gearbox linkage. From memory there is a screw holding the gear lever to the linkage.

At this point the gear lever shaft won't pull out as it is still seized! Plenty of freeing agent light oil and patience plus lots of wiggling worked for me. Cleaned the shaft with fine emery cloth and regreased. No probs for ages (will have now I've posted this!)
Click to expand...

the drawings for the 4 stroke do not show a plate like the 2 stroke. Links to both already given in preceding posts
 
i've looked at the engine and Vic is correct - i'd have to remove the power head to access the gear linkage.
I've since spoken to Tim Barret at EH Barrus, who was very helpfull. He confirmed that the gear lever/ linkage is not designed to be user servicable & that as the engine is less than 2 years old it's covered under Warranty. In spite of the fact that we bought the engine in N Spain and are now in S Spain, Tim couldn't have been more helpfull.
The problem we have now is that the seller hasn't registered the sale/ warranty and until that's done i can't get the work done under warranty. I'm working on that issue. Wish me luck!

John
 
With my Yamaha 5 T/S I found initially I put a tubular spanner on the lever - it worked easily & well - I keep it handy.
 
There could be a bottom end problem but much more likely is that the lever pivot shaft is simply seized at the top. Two small bolts undo a cover over the gearshift lever inner end, and then after removing a Philips head screw, you can prise it out, lubricate it and put it back. Have to do that every year on mine, or it gets stiffer and stiffer to engage gear. Did this last week!

This is the advise I got last year from jwilson. It worked, what can I say

Dave
 
kunyang said:
There could be a bottom end problem but much more likely is that the lever pivot shaft is simply seized at the top. Two small bolts undo a cover over the gearshift lever inner end, and then after removing a Philips head screw, you can prise it out, lubricate it and put it back. Have to do that every year on mine, or it gets stiffer and stiffer to engage gear. Did this last week!

This is the advise I got last year from jwilson. It worked, what can I say

Dave
Click to expand...

No cover plate on a 3.5 HP 4 stroke Merc...the subject of this thread....
 
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