Mercury (Tohatso etc) 3.5hp stiff gear lever problem

[EugeneR]

The gear lever on my Mercury 3.5hp 4-stroke has become stiff, to the point that it's not really usable.

I removed the head and linkage to the gears, so I'm am certain the problem is with the lever, but I cannot find any way of removing it.

Unlike the 2 stroke, it does not look like this one has a plate with screws that can be removed, and there does not appear to be a greasing nipple either. I had a look at the parts diagram but it does not show anything either.

Unlike the previous poster on this topic here, the engine is no longer under warranty so that's not a solution either.

Has anyone else had the same problem and managed to get it fixed? Or know how to remove the gear lever?

It seems to be a common issue, although I cannot find the solution anywhere...

 

[superheat6k]

I guess penetrating oil and a lot of wiggling back and forth. Once it loosens a spray chain lubricant or PTFE spray well worked in should keep it free.

 

[Fishtigua]

There are lots of linkages on the 3.5, all need a quick lube from time to time.

My 2.5 needs a jiggle on occasion.

http://www.tohatsu-nissan-parts.com/Parts%20Catalogs/TOHATSU/2-Stroke/Parts%20Catalog%20M2.5A2-3.5A2-3.5B2%20%20(2003)%20-%20(00221040-4).pdf

 

[jwilson]

Common problem - easyish to fix - see http://www.lakelandimages.co.uk/Forum pics/info_engine/Tohatsu/ for the manual - it's the "mid-section" file you want. Thanks to Lakesailor for hosting these, I've had to free mine up twice in 7 years. The Mercury/Mariner/Tohatsu 3.3/3.5 two stroke engines are all the same under the badged cover.

 

[VicS]

I think Lakesailors file and Fishtigua's link refer to the 2 stroke but the 4 stroke is pretty much the same see http://www.boats.net/images/diagrams/tohatsu/MFS2B-3B-2009-fig-12.png

If you can, fit a grease nipple so that the lever can be lubricated .. otherwise oil it regularly

I'd guess the 4 stroke with no oil in the fuel, might be more prone to this than the 2 stroke.

My Evinrude has a grease nipple... and Its something I am careful not to miss when giving it its annual service

 

[EugeneR]

It seems to be a common problem but, for the 4 stroke, I still don't have a solution.

After lots of W40 at least the lever can move again, however it's still rather stiff.

 

[forelle541]

On mine I took the o rings off and it was better, it's as if the shaft has swollen.

 

[EugeneR]

On mine I took the o rings off and it was better, it's as if the shaft has swollen.

Was this the 4 stroke and, if so, how did you get to the gear lever O-rings?

 

[oburrell]

I got an old Tohatsu 3.5 B2 (basically for free) and the gear shift lever was so swollen that I had open the grease chamber, take out the screw to the gear lever that goes down to the gear box, then lever it out with two screw drivers between the lever handle and the housing. It was so stiff that it took me half an hour and a lot of swearing! I used WD40 for lubrication but it didn't do much. What you can do if you get the lever out in one piece and not too damaged ... grind it down with sandpaper. Maybe start at 200 going down to 600. Take off the rubber rings first and put them back on after the grinding. If it was damaged too badly in the process you might be able to buy it on eBay. Use the right lube that is defined in the service manual and you will not have this problem. The wrong lube will swell the lever up and it will become stiff. Good luck with this ...

 

[greeny]

Fully agree with all you say and the problem and solution is very common. But are you aware that this thread is 9 years old so doubtful the OP is still interested.