ObiwanKenobi
Cadet
- Joined
- Feb 10, 2017
- Messages
- 19
Not realizing it was against policy, I posted this in a thread that was too old. Reposting now because I think it could help someone. I did the steps and got it done in 15 minutes.
Writing this for the benefit of those who may encounter this problem and are searching Google for a solution...
Depending on your motor, you may be in for the most frustrating DIY of your entire life. If the U-shaped yolk that sits in the rod that moves the clutch dog has become unseated, you have to take it apart from the top. That's the easy part. On my 1994 Force 120, the mechanism at the bottom of the shifting rod--the one that the pivot screw goes into--BARELY fits through the space above the area where it eventually sits. If you want to line it up and then drop it straight down, you would have to do some grinding. It took my mechanic literally about five hours to do. The second time around, it was quick and easy. (The world would also benefit from a description of a better method, so please feel free to decry my method and suggest a better one.)
1. With the oil drained, the shifting rod completely removed, and the yoke sitting in the 90 degree mechanism that "holds" it, string a piece of fishing line so it holds the yoke in place and also lifts the 90 degree thing. (Ideally, you want two fishing lines--one to guide the yolk and another to guide the 90 degree holder, but unless you're General Grievous, you only have two hands, and you need one to insert the pivot screw.)
2. Lower the entire rod assembly in, preferably while wearing a headlamp. Use the fishing line to align the yolk with the notch in the rod that moves the clutch dog below. Make sure the yolk sits there nicely.
3. Using a hammer, tap the top of the shifting rod to slowly put it in place. Be careful to keep it lined up vertically with the pivot screw hole.
4. While looking through the pivot screw hole, you're going to see part of the hole the screw has to be inserted into. When you see that, insert an awl, a nail, or something else. Then use the inserted pointy object to properly align the hole. At this point, some or all of the resistance caused by the awkwardly angled cavity the shift rod assembly has to slip into should go away. If it doesn't, just keep tapping the awl or nail anyway.
5. Once the holes are aligned sufficiently, insert the screw.
A better method may be appreciated by searchers, so please feel free to suggest it. This worked very well for me, however, so I hope it helps someone.
Writing this for the benefit of those who may encounter this problem and are searching Google for a solution...
Depending on your motor, you may be in for the most frustrating DIY of your entire life. If the U-shaped yolk that sits in the rod that moves the clutch dog has become unseated, you have to take it apart from the top. That's the easy part. On my 1994 Force 120, the mechanism at the bottom of the shifting rod--the one that the pivot screw goes into--BARELY fits through the space above the area where it eventually sits. If you want to line it up and then drop it straight down, you would have to do some grinding. It took my mechanic literally about five hours to do. The second time around, it was quick and easy. (The world would also benefit from a description of a better method, so please feel free to decry my method and suggest a better one.)
1. With the oil drained, the shifting rod completely removed, and the yoke sitting in the 90 degree mechanism that "holds" it, string a piece of fishing line so it holds the yoke in place and also lifts the 90 degree thing. (Ideally, you want two fishing lines--one to guide the yolk and another to guide the 90 degree holder, but unless you're General Grievous, you only have two hands, and you need one to insert the pivot screw.)
2. Lower the entire rod assembly in, preferably while wearing a headlamp. Use the fishing line to align the yolk with the notch in the rod that moves the clutch dog below. Make sure the yolk sits there nicely.
3. Using a hammer, tap the top of the shifting rod to slowly put it in place. Be careful to keep it lined up vertically with the pivot screw hole.
4. While looking through the pivot screw hole, you're going to see part of the hole the screw has to be inserted into. When you see that, insert an awl, a nail, or something else. Then use the inserted pointy object to properly align the hole. At this point, some or all of the resistance caused by the awkwardly angled cavity the shift rod assembly has to slip into should go away. If it doesn't, just keep tapping the awl or nail anyway.
5. Once the holes are aligned sufficiently, insert the screw.
A better method may be appreciated by searchers, so please feel free to suggest it. This worked very well for me, however, so I hope it helps someone.