Outboard Wizard Required

[LONG_KEELER]

I have changed the water pump impeller on my Mariner 6hp 4 Stroke 2008 outboard.

I just can't get the leg back on the outboard. You have to marry up the drive shaft into the splines, water pipe connection and gear rods.

The problem seems to be meshing the splines together. I'm about two inches short. I have tried turning the prop by hand when offering up the drive shaft but she just won't go. Do I need the gear lever in a particularly position when offering up and or perhaps tie it off ? It's very difficult to see anything with a torch and it's a long shaft.

Any tips would be most grateful received.

 

[Martin_J]

Have a coffee, take quick look at the forum, then go back with a fresh view and it might just slot into place...

That seemed to work for me in the past. Sorry can't help further.

 

[VicS]

I have changed the water pump impeller on my Mariner 6hp 4 Stroke 2008 outboard.

I just can't get the leg back on the outboard. You have to marry up the drive shaft into the splines, water pipe connection and gear rods.

The problem seems to be meshing the splines together. I'm about two inches short. I have tried turning the prop by hand when offering up the drive shaft but she just won't go. Do I need the gear lever in a particularly position when offering up and or perhaps tie it off ?

Any tips would be most grateful received.

The driveshaft wont turn when you turn the prop unless it is in gear ..... but the gear lever wont have any effect until the upper and lower rods are reconnected.
Pull the lower rod up to ensure it is in ( forward) gear

 

[LONG_KEELER]

The driveshaft wont turn when you turn the prop unless it is in gear ..... but the gear lever wont have any effect until the upper and lower rods are reconnected.
Pull the lower rod up to ensure it is in ( forward) gear

Will do. As Martin has suggested, I will give it a rest and have another go tomorrow .

 

[QBhoy]

Yeah. Double check that gear linkage I’d say. And make sure not only the drive shaft is aligned…but the pump outlet is too.

 

[Boathook]

Normally the shaft reaches in first which allows the gearbox to be rotated a bit to align the splines. The water pump bits then meet up and finally you are left with the gear change that normally has anough slack to fit together. This is for my Malta and Honda 30.

 

[Milgrip]

It's just a matter of perseverance. If the drive shaft does not slot in, lower the leg and rotate the shaft a little by hand and try again.

 

[LadyInBed]

Instead of offering it up, turn the engine upside down and lower the prop assy in. That way, the rods are more inclined to mate up.

 

[Beneteau381]

I have changed the water pump impeller on my Mariner 6hp 4 Stroke 2008 outboard.

I just can't get the leg back on the outboard. You have to marry up the drive shaft into the splines, water pipe connection and gear rods.

The problem seems to be meshing the splines together. I'm about two inches short. I have tried turning the prop by hand when offering up the drive shaft but she just won't go. Do I need the gear lever in a particularly position when offering up and or perhaps tie it off ? It's very difficult to see anything with a torch and it's a long shaft.

Any tips would be most grateful received.

Fiddle with a thin rod and needle nose pliers, grip the gear shift rod etc and wriggle. wiggle the flywheel by hand. There is no definitive answer, tou have to get 3 ducks in a row

 

[VicS]

Instead of offering it up, turn the engine upside down and lower the prop assy in. That way, the rods are more inclined to mate up.

Drain the engine oil before trying this

Fiddle with a thin rod and needle nose pliers, grip the gear shift rod etc and wriggle. wiggle the flywheel by hand. There is no definitive answer, tou have to get 3 ducks in a row

You have to disconnect the starter lockout linkage and remove the recoil assembly in order to access the flywheel, but doing so is described in the owners manual.

 

[Steve65]

Easiest way, sounds a bit drastic is remove powerhead. Then its just gear linkage . Dont worry about water pipe. You can remove that and the grommet then by looking down the leg relocate it into the pump housing. Then replace the powerhead.
You will poss need a base gasket but you will be able to clean some of the waterways

 

[QBhoy]

Jeez…think we are going a little OTT perhaps? It’s just needing patience and a fiddle, I’d think. As said by many previously. As well as what I and others have suggested…make sure you aren’t getting hung up on a locating dowel that marries the lower unit to the mid section at their mating surface. That’s if it has any. Some certainly do.

 

[Beneteau381]

Drain the engine oil before trying this


You have to disconnect the starter lockout linkage and remove the recoil assembly in order to access the flywheel, but doing so is described in the owners manual.

Ive done it for a friend, have you?

 

[Beneteau381]

Easiest way, sounds a bit drastic is remove powerhead. Then its just gear linkage . Dont worry about water pipe. You can remove that and the grommet then by looking down the leg relocate it into the pump housing. Then replace the powerhead.
You will poss need a base gasket but you will be able to clean some of the waterways

How much is a base gasket? I did a two stroke Yam a year or so ago, unobtainium in UK, £50 ish from NL.

 

[simonfraser]

lubing all the mating components is likely to help too

 

[Milgrip]

Try this (see attachment) and don't forget to disconnect the spark plug cable first

 

[Steve65]

Base gaskets are not expensive, for this model I usually pay around £9

 

[LONG_KEELER]

Feedback

After 2 hours of trying everything yourselves and I could think of, I will have to admit defeat. You would think it would be like pushing a prop onto splines but smaller and .6m away. I did not connect any gear rods and made sure there was no fouling at the top of the gearbox rod onto the leg or water pipe.

One thing that I could not explain , the unconnected gear lever on the engine always moved to the forward gear position whenever the gearbox drive shaft was presented to the splined connection. Perhaps the guidance bracket inside the leg is distorted or the leg itself.

I even tried 6mm and 8mm threaded bar temporarily substituted for the two bolts holding the leg and slid the gearbox unit on and turned the drive shaft with added wiggling and shaft turning.

I am probably going to take the two parts and present them to an outboard dealer and eat humble pie.

Is there much work involved on more dismantling suggested by steve66 ?

Anyway, thanks for the suggestions from you that I would never have thought of and I will live to fight another day.

 

[Steve65]

Feedback

After 2 hours of trying everything yourselves and I could think of, I will have to admit defeat. You would think it would be like pushing a prop onto splines but smaller and .6m away. I did not connect any gear rods and made sure there was no fouling at the top of the gearbox rod onto the leg or water pipe.

One thing that I could not explain , the unconnected gear lever rod on the engine always moved to the forward gear position whenever the gearbox rod was presented to the splined connection. Perhaps the guidance bracket inside the leg is distorted or the leg itself.

I even tried 6mm and 8mm threaded bar temporarily substituted for the two bolds and slid the gearbox unit on and turned the drive shaft with added wiggling and shaft turning.

I am probably going to take the two parts and present them to an outboard dealer and eat humble pie.

Is there much work involved on more dismantling suggested by steve66 ?

Anyway, thanks for the suggestions from you that I would not have thought of and I will live to fight another day.

Half a dozen bolts

 

[LONG_KEELER]

Half a dozen bolts

Like these under the outboard ?


Would the nuts inside the cover be reasonably accessible ?

Thanks

EDIT.
It doesn't look too bad . I'm tempted.
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