outboard motor gear lever sheared off -

C

Cloona

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tomorrow is the first day of weeks hols .....

and the plastic gear lever on my Sailmate outboard has sheared off -

.... NO COMMEMT on the design and engiineering of this ....

There is a small rump of plastic left stuck on the metal knob, the rest of it is in my hand -

Any suggestions for a fix to get me through the week ?
 
Is that a Mercury/Mariner?
First stop a dealer,

second on the web and special delivery,

third borrow or hire and outboard,

fourth depends on your resources but remove the stub and find something that will clamp to the shaft, or something you can epoxy bond to the stump (preferably around) that will act as a gear lever. Get something longer than the original as you can more easily coax it in and out of gear, thus less risk of it coming off.

fifth depending on your mechanical skills, use mole grips or similar to get it into forward and detach the interlock that prevents starting in gear. Use it like a small ouboard with no gearchange.

Oh, does the gearchange have any external components on the leg that you could use to change gear?
 
Nothing much more to suggest by way of a temporary bodge. Can you drill and tap a hole in the plastic that's left and thread in a bolt.

As far as permanent repairs go that is a Mercury or Mariner I believe.

There are exploded diagrams HERE (and I am sure other places as well) that will enable your to identify the exact parts and part numbers you need. They give a pretty good indication of how everythig is fitted together as well.

Wills Marine have proved to be good for Johnson/Evinrude parts by mail order. They also do Mercury spares but not sure about Mariner.
 
Good News.

Here is a pic of the gear shift. If it has broken where I put the yellow line which is most probable, you could find a tube to slip over the stub, drill a few holes in the wall and pack it with car repair paste/grp repair paste and push onto the grooved remains of the lever (not forgetting to put a bend in the tube first to act as a lever)
In 20 minutes when it sets it should be a reasonable fix. Dont try to remove the plastic stub as it houses the detent spring for the gearchange, and seems to be glued to the shaft anyway.

Gearshift.jpg
 
I don't know if you can get to a Maplins shop, but they sell some stuff called Polymorph..
http://www.maplin.co.uk/Module.aspx?ModuleNo=35511&doy=27m7

It's plastic granules that you can melt by putting in a bowl and pouring boiling water over and then mould to the shape you want. It sets to look and feel quite like hard nylon plastic

Wikipedia says.

.Polycaprolactone plastic, sold under the name "Polymorph" and "Shapelock", is used in modeling and DIY on a small scale. It is a very tough plastic at room temperature, with a very good impact resistance and tensile strength, however when heated to 62*C it becomes a rubbery, mouldable putty. It is very useful for repairing plastic objects because of the way it sticks to them well when hot. If sticking is not desired then the outer layer can be cooled with water and the inside will remain pliable.

Might do the trick ?
Good Luck
Bill
 
Re: Lake Sailor

That was the good news. The bad news is that if your set up is as per Lake Sailor's diagram, then when you get back you will have to remove the power head in order to replace the gear lever.
 
Re: Lake Sailor

Happened to me a few months ago. I tried drilling and tapping but its just not strong enough. In the end I managed to get it into forward gear and left it there (you have to disable the interlock on the starter puller thingy to get it to start). Just be really really careful that the throttle is closed when you start it!!!!!!
 
Re: Lake Sailor

That was my fifth suggestion, but I thought the H&S police on here may shout me down. Good to know it worked for you.

Drascomber. Don't be ridiculous, the repair will never stay on for a whole week /forums/images/graemlins/grin.gif /forums/images/graemlins/grin.gif
 
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