Small outboard re-assembling

[Roberto]

I just changed the impeller of my small 4hp 2stroke Yamaha outboard (it only had one blade left /forums/images/graemlins/crazy.gif), and I lost almost two hours trying to re-assemble the engine lower unit to the upper one.

When the propeller base is dis-assembled from the engine, there are three rods: 1.the transmission shaft, 2.the water conduit, 3.the gear rod (the one used to engage from neutral to reverse or forward);
now, when reassembling the two units, the three rods must engage each one in a different hole, and short of having four hands with fifteen ultra thin fingers, it takes a very long time for a rather simple job

does anyone know a trick to make things easier ?

 

[Talbot]

if you change the gear, the different length of the gear rod should enable you to engage one of the three, then the next, and finally the third.

 

[andy_wilson]

As an engineer always used to say to me...

Grow hairs round the hole.

 

[Roberto]

problem is the three rods only begin to engage when the lower gearcase is so near to the engine body that it is practically impossible for my fat fingers to keep any rod in position... ideally, there should be a sort of template to keep them in position while putting the lower gearcase back up, I thought about putting a piece of cardboard but then I am afraid with use it might disintegrate and make things worse..

 

[Roberto]

Re: As an engineer always used to say to me...

this engine must be of a self-shaving type /forums/images/graemlins/blush.gif

 

[Talbot]

so make a paper template to hold them in the right place and when engaged, pull the paper out.

 

[William_H]

With my Johnson the gear shift rod pushes and pulls up and down. Now if the rod in the gear box is pulled out (up) and the gear lever is moved to the position where gear rod is out (down) then it is connected with a 1cm gap. When you bolt it together the lever moves to the correct position.
The water tube is guided into a rubber tube and the shaft you just fiddle to get it into the spline at the power head. So yes on a johnson it is a bit tedious but not too difficult. Of course yours may be much different but the gear lever trick mayu be applicable and you may not have used it... olewill

 

[Roberto]

thanks a lot! my engine must be very similar to yours, your description fits very well -.<)
Next time I ll try the gear lever movement, and put a small piece of hose to guide the water pipe into its rubber encasing

cheers /forums/images/graemlins/laugh.gif