Yamaha 4 HP 2 stroke gear lever broken off

[john_q]

I have managed to break off the plastic gear lever for my outboard flush with where it goes into the engine, (The dinghy got caught under a dock in rough conditions.)

As I understand it, to fit a new gear shift, means that I have to remove the power head which I would like to avoid at the moment. I have managed to retrieve the broken off “L” shaped lever from under the dock

Has anyone had success in re joining gear levers or has some suggestions as to how to re join the 2 bits of plastic together?

 

[lw395]

I've mended similar things by drilling right through, tapping threads and putting in a length of studding.
I then found a new item on eBay for about £2!

 

[Seajet]

John G,

I have a Yamaha 4 as a backup engine stored at home; the gearshift on these is notorious.

My ace engineer Father drilled a hole in the gearshift to allow oiling it, before we did something like shearing it.

I can picture the gearshift in my mind, I think with luck you could re-attach the lever with a decent self tapper and maybe some araldite, but lubricating the thing is essential or it'll happen again very promptly.

I'll have a look at the engine when I'm there later, if I or Dad have any bright ideas, we'll pass them on ASAP.

For a complete replacement, Ron Hale Marine at Portsmouth may well be able to supply it; I do realise you are not exactly within walking range !

 

[david_bagshaw]

been there, brother wound dingy into davit, snapped it & did not tell.

found out when enging needed in a hurry, & it fell off in my hand!!

shortened its replacement so it wouldnt snagg.


The power head is not that difficult to remove, the gear change grip bolt in the leg and the power head bolts, and the clamp over the gear lever,

total time, less than 1 hour

 

[Seajet]

John,

after a look at my engine and chat with Dad, we reckon you WILL have to remove the powerhead, but it shouldn't be too much hassle.

One thing is that the drive from the engine is plain steel, going into a stainless spindle, be sure to separate the gearshift clamp inside the leg, then - with the engine well drained of any water - turn it upside down, and remove the rubber plug on the leg.

Squirt in plenty of WD40, or oil with petrol, etc and if poss' give it a while.

If having trouble separating the leg, once a gap is there one could drive in wooden wedges, gently !

Having done this on a freinds' engine, I can say it seems like it will never separate ( a pro' mechanic gave it up as a write off ) but eventually with perststence it all happens.

In a perfect world you'll need gaskets, again Ron Hale in Portsmouth would be my place to go to.

Have Fun & Good Luck !

Andy

 

[Blueboatman]

There is a way, my old Mariner5 succumbed before I fitted a grease nipple, but it involves longitudinally drilling to insert a stainless rod then drilling two pins into that so unless a happy DIY sort of chap I would just get a mechanic to quote. Boring tho innit

 

[ostell]

Had the same problem. Gear lever seized and came off in my hand, hard grease stops lubrication and shaft had seized. Splitting looked daunting but I encountered no problems. Spares from Ron Hale.

 

[john_q]

Thanks for your comments. I am currently in Belize Central America so I have ordered a new gear shift (2 – 3weeks to arrive from the States maybe) and am currently using the engine with it in forward gear so it makes starting and leaving docks more fun.

Once the parts arrive I will have a go at fitting the new gear lever and maybe try to mend the broken one as a spare

 

[Thedigger]

Hi,
My Yamaha 4AS wouldn't go into gear and I drifted into the rocks. I took off the top split the leg from the clamp took off the cap from the propeller. But can't access the gear shaft to see why is it stiff and will not engage. The 2 stroke is second hand pretty old

 

[VicS]

Hi,

You have resurrected and hijacked an old thread;

You might do better starting a new thread of your own

 

[david_bagshaw]

Hi,
My Yamaha 4AS wouldn't go into gear and I drifted into the rocks. I took off the top split the leg from the clamp took off the cap from the propeller. But can't access the gear shaft to see why is it stiff and will not engage. The 2 stroke is second hand pretty old

usually stiff engagement is caused by the selector rod corroding it self in the lower leg....
start there.

if you are lucky there might be a rubber grommet that gives you access, to lift the rubber bit and apply some oil. and jiggle it about.

 

[Thedigger]

You have resurrected and hijacked an old thread;

You might do better starting a new thread of your own

Hijacked!