Tohatsu 3.5 hp "gear lever" snapped off -

B

Blue Nun

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www.roryowen.co.uk
Tohatsu 3.5 hp \"gear lever\" snapped off -

Brilliant outboard but... /forums/images/graemlins/tongue.gifI've snapped the lever off my new outboard and the supplier can't get hold of a new one for a week to 10 days.

Does anyone know anyone who keeps Tohatsu parts in stock?
Is it easy to replace?
Is there a repair manual online?

Many thanks
 
Re: Tohatsu 3.5 hp \"gear lever\"

It's the one weak point in an otherwise excellent engine.

Mine gives continuous trouble seizing in the plastic bush, only working for about 5 times or a couple of days, when I drench it in penetrating lubricant

I even stripped the leg to see if there was anything else amiss.

Any new one you have will go the same way and, if yours is like mine you'll have to chisel the thing out.

Lower down the leg is a rubber "bung" behind this is the clutch linkage and the driveshaft - clutch is the one with a double clamp on it. Insert a screwdriver and use that as the actuator - down is clutch disengaged, up is clutch engaged.
Personally I'd not bother to replace it, I only disengage the clutch to stow the engine and use it as a permanaently in-gear outboard.

PS You must have used a lot of brute force (or even a lever) to break it, mine has merely bent.
 
Re: Tohatsu 3.5 hp \"gear lever\" snapped off -

I snapped my lever when my 3.5 fell on its side. I guess its better that the plastic should fail rather than the bolt get bent, but it is a pain. The motor will start in gear given a good enough pull, so suggest you work with it in gear until a replacement is available.
 
Re: Tohatsu 3.5 hp \"gear lever\"

I had problems with the lever sticking so posted the problem here a couple of weeks ago. Within minutes I had detailed instructions and had removed, cleaned and re-greased and it now works fine. /forums/images/graemlins/smile.gif /forums/images/graemlins/smile.gif /forums/images/graemlins/smile.gif
 
Re: Tohatsu 3.5 hp \"gear lever\"

Had a 5 that got stickier and eventually snapped,so I drilled out both pieces and inserted a75mm length of 4m s/steel rod and then drilled tiny pegs sideways into that ,drilled and fitted a grease nipple(local car shop), bent and screwed a piece of flat ally 25mm bar around the shift lever ,self tapped into the lower engine casing ,this took the weight off the lever when lying on its side.
 
Re: Tohatsu 3.5 hp \"gear lever\" snapped off -

Could you use a pair of Mole Grips as a temporary botch, until you are able to get the proper part?
 
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