Hello everyone, I'm new to the forums and would like some experienced opinions on a shift issue I can't seem to resolve. Here's a quick summary:
1987 BAJA
205HP/4.3 MERC
ALPHA ONE/GEN. ONE
Installed a new lower cable last July which currently does not bind and will shift the drive easily when unhooked from the kill switch assembly and upper cable. Kill switch works and adjusted out to 1/8 inch travel. New control box installed last July as my old one finally gave out after 20 years. Installed a new impeller kit last week and realigned shift shaft to mate up with shift lever(pointing forward). Adjusted both cables out according to Merc specs(6 inches center to center on lower cable) and spent last Saturday on the lake until I noticed that the travel required to shift the boat into FWD was requiring more and more travel until it was all throttle and no shift. Reverse was no problem.
Pulled the boat from the water, replaced the upper cable last week( once again a 20 year old part), adjusted to specs again and can't seem to find the sweet spot without the clutch dogs clicking and a slight increase in throttle. Finally it will catch in both, however it requires too much control handle travel and a firm clunk from the dogs which we all know is not a good thing.
Question at hand: Does this sound more like a bent shift shaft,Shift shaft lever issue or some other issue? Something I overlooked?
1987 BAJA
205HP/4.3 MERC
ALPHA ONE/GEN. ONE
Installed a new lower cable last July which currently does not bind and will shift the drive easily when unhooked from the kill switch assembly and upper cable. Kill switch works and adjusted out to 1/8 inch travel. New control box installed last July as my old one finally gave out after 20 years. Installed a new impeller kit last week and realigned shift shaft to mate up with shift lever(pointing forward). Adjusted both cables out according to Merc specs(6 inches center to center on lower cable) and spent last Saturday on the lake until I noticed that the travel required to shift the boat into FWD was requiring more and more travel until it was all throttle and no shift. Reverse was no problem.
Pulled the boat from the water, replaced the upper cable last week( once again a 20 year old part), adjusted to specs again and can't seem to find the sweet spot without the clutch dogs clicking and a slight increase in throttle. Finally it will catch in both, however it requires too much control handle travel and a firm clunk from the dogs which we all know is not a good thing.
Question at hand: Does this sound more like a bent shift shaft,Shift shaft lever issue or some other issue? Something I overlooked?
