Putting an outboard back together

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NorthRising

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Yamaha F6C 4 stroke long shaft

I thought I'd save some money and service my own outboard - bad move, perhaps...

Good news is got it apart without rounding any bolts or nuts. Fitted new impeller, and put back water pump casing etc. However, I cannot for the life of me get the top of the drive shaft to slide up into place in the power head. I can get the water way into the top of its grommet, and can get the gear shift into its hole and clip. But I can't get the gearbox casting to meet with the casting above, I have a gap of about 2 inches. I'm sure that it is the top of the driveshaft that is not slotting into its housing, but can't work out why.

Anybody got any tips? Meantime I need a Whisky.....
 
Try turning the propellor a bit when you get to the sticking point. (Put it in gear first if it isn't.) Might help line up the splines correctly.
 
NorthRising said:
Tried turning the prop, to no avail so far, but worth another go tomorrow.

This video is of impellor change on same model:http://m.youtube.com/watch?v=k_DV8UrnYrQ
Click to expand...

Was it in gear? .... at ths point you have not reconnected the gear shift. Try turning the flywheel ( with plugs removed)

The first time I changed a pump impeller it took a while to get the drive shaft into the crankshaft but then it went in so suddenly I took it apart again to see if I'd broken anything!


Interesting video but fails to show the new impeller and drive key being fitted.!

glosses over reconnecting the shift shaft I thought

does not suggest a smear of grease on the gearcase retaining bolts or on the drive shaft splines.
 
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Correct, at this point the gear shift shaft is passed through its clamp, but the clamp not tightened. I have tried to put the driveshaft in, while in forward, reverse and neutral; to no avail so far.

Indeed the video is cut at a few key moments.

Will have another go tomorrow.
 
NorthRising said:
Correct, at this point the gear shift shaft is passed through its clamp, but the clamp not tightened. I have tried to put the driveshaft in, while in forward, reverse and neutral; to no avail so far.

Indeed the video is cut at a few key moments.

Will have another go tomorrow.
Click to expand...



Make sure that when you turn the prop the drive shaft really is turning. Other wise turn the engine/ crankshaft with the flywheel instead until the splines line up
 
I give in; time to swallow my pride and pay a mechanic.

I now have fine metal filings in the grease at the splines on the driveshaft; don't want to do any further damage.

Maybe it's just me, but I'm somewhat scornful of suggestions I've seen elsewhere on this forum, that those with outboards should be able to change an impellor in a seaway, I've failed with the outboard on a stand in a workshop....

I won't be trying to save money by diy in future.
 
NorthRising said:
I give in; time to swallow my pride and pay a mechanic.

I now have fine metal filings in the grease at the splines on the driveshaft; don't want to do any further damage.

Maybe it's just me, but I'm somewhat scornful of suggestions I've seen elsewhere on this forum, that those with outboards should be able to change an impellor in a seaway, I've failed with the outboard on a stand in a workshop....

I won't be trying to save money by diy in future.
Click to expand...

I am totally bewildered. It should be a piece of cake.

There are only three things that have to line up.

The water tube with the pump outlet, which you can see anyway

The shift rod with the clamp, which you can see to some extent

and the drive shaft with the crankshaft. Thats the only bit you cannot actually see


I think Id look a bit more closely at the shift rod just to make sure it is entering the clamp correctly but I think you must be failing to aim the drive shaft at the end of the crankshaft properly and missing it altogether.

Can't think how you are getting metal filings on the spline :confused:


However please be sure to ask your mechanic what was causing the problem and let us know.
 
I wish it was a piece of cake.

The only cause of metal fillings I can see is from turning the two sets of splines against each other to try and get them aligned.

I can see the gear shift is clearly passing through its clamp, I can see the waterway just entering its grommit on the pump, I can see the driveshaft turn when I rotate the prop. So I like you VicS believe the problem lies in spline alignment. I've tried rotating flywheel in gear (plug out) as alternative to rotating driveshaft.

After 2 hours yesterday and also today my confidence us somwhat dented.

Thanks though for all the suggestions.
 
After a bottle of Colonsay brewery 80/ and another extra pair of hands the driveshaft miraculously slid into place as easily as early attempts were frustrating: as was suggested when it worked it was like a piece of cake...
 
NorthRising said:
After a bottle of Colonsay brewery 80/ and another extra pair of hands the driveshaft miraculously slid into place as easily as early attempts were frustrating: as was suggested when it worked it was like a piece of cake...
Click to expand...

Good.

Hopefully no problems connecting the two parts of the shift rod to get the gear change working correctly.

Or is it impossible to get it wrong, or did you mark it before disassembly ?
 
Hard to explain, but the shift clamp is angled, so it is clear where each part should sit. Good point about marking, which I didn't do... But I've had the engine running and the gears are working fine.
 
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