Lower leg- Forward neutral reverse Merc 500

[PlayDoh]

I had to change my impeller when I first got the motor, and ever since I've been unable to put it back together correctly.

When I first tried, I got forward and neutral, but no reverse. Lived with that for a year. Now I found an older thread with someone explaining how to best re-install the lower leg.

Now I need to figure out what position to put the lower leg shift shaft to, and the two 'cams'? positions. The pictures below show the lower leg removed, and the two 'cam' pieces separated and set to the right of the lower leg.

The two cams, activate the motors 'tilt lock', but they don't seem to line up properly with the motor in neutral. I might try and install the lower leg with both ends in either Forward, or reverse, since the lock wasn't working right last attempt.

I wish I had a chance to mark everything when I first took the lower leg off, but the two pieces fell out and onto the ground and I turned the gear shaft on the lower leg when I was working on the impeller.

I've tried turning the lower legs shift shaft in either direction, till I find neutral, then re-install it. There seems to be 2 neutrals 180 degrees from each other, but I'm not 100% clear on that. I've had it where forward is reverse, no forward or reverse, or only forward and reverse, all from different positions.

I can't see how its this difficult, since if both are in neutral, how can it not shift properly? I figured out how to adjust the shift cable (picture with red arrows), and once when reverse didn't work I jammed it hard and it went into gear. Also when I first put the lower leg together I had reverse the first time, but not after.


Thanks for any help.

 

[PlayDoh]

Re: Lower leg- Forward neutral reverse Merc 500

Man, this is quite the pickle. I've had the lower leg off and on, over a dozen times but still no joy.

Now I can get forward, neutral & reverse, but forward and reverse are backwards. Even the 'tilt lock' is ***** backwards, locking in reverse but not forward.

I'm wondering if removing and installing the lower leg in neutral is the correct way? Since I've put it in neutral, dropped the leg, turned the lower leg shift shaft, and try to find a "different" neutral or position, and putting the leg back on and checking the 3 gears/positions.

I've tried all I can think of, but I'm not giving up yet.

 

[PlayDoh]

Re: Lower leg- Forward neutral reverse Merc 500

Finally! I found out that I've had it the right way probably half a dozen times, but I expected the prop to turn clockwise, while turning the motor over, but its supposed to make a ratcheting noise, and click while turning around.

Heres the post I found

Chris1956
In neutral with the motor off, the prop should turn freely in both directions. In forward the prop should turn CW with a ratcheting sound. In reverse, eh prop should turn less than one turn in either direction, before stopping.
http://forums.iboats.com/showthread.php?t=252012&highlight=forward+is+reverse

For me, when its in reverse the prop will turn, but you have to turn the motor over. I'm probably lacking in cylinder pressure, and its only a 50 HP, so if it was a large motor I wouldn't be able to turn the prop in reverse and Chris1956's advice that the prop will 'stop' would be how it is.

For anyone who's having any of the trouble I had with re-installing the lower-leg feel free to PM me or Email me. playd0h@telus.net

I feel your pain.

I'll sum it up quick.

Put both the motor and lower leg in Neutral. The lower leg will stay in Neutral, and have to 'click' out of Neutral when its in the right position. Turning the lower legs shift shaft clockwise, should put it in Forward, & vice versa. You might want to check your own linkage though.

Now, the problems I had started when I tried to fit the leg back up. I take the spring off the motors 'tilt lock' so I can swing up the lever, and put the top 'cam' up in the upper leg before I start. I put the lower cam on the lower leg, which I can't remember how I figured out its proper position, but I do know that its much easier with the 2 peices on both ends of the leg.

First, You put the drive-shaft up and in to its hole (spline) that you can't see. You have to make sure the 'tail-fin' bolt goes through the hole, next. Then start pushing the leg up.

If the leg hits something before you can thread a bolt on, you'll have to turn the fly wheel a wee bit (clockwise). Let the leg out a bit so it lets the fly wheel turn the inner splines, turn the fly wheel with your right hand up through near the top plug, at the back of the motor, while holding on to the leg with your left.

Try to jiggle/jostle/shake the lower leg while trying to push it up after every nudge of the fly-wheel.

That should get the drive-shaft completely in to its spline, and it should move up enough to put the 2 Up-most/highest nuts on just a few turns. Make sure their both on, before you start to tighten it up. Also make sure your water hose/tube fit in to the impeller housing, earlier.

Now, chances are the shifter shaft hasn't fit in to its upper spline. So I turn the rear-most nut/screw/thingy at the very end of the shift linkage. You turn it 90 degrees and it will pull out, allowing you to move the shift linkage (motor side) with your hand. Just wiggle it, don't move it back and forth very far. I never heard a click, or could tell it finally fit in, other then when you push the leg up, or tighten the bolts, it was more difficult then it should be.

You should be able to shove the leg all the way up, but its not easy even when everything is aligned, so you can tighten the nuts to bring the two halves together (unless you like hernias), but make sure it comes together fairly easy. For example, if you forget to put the tail-fin bolt through its hole, it can sit ****-eyed and you could warp or crack the leg if you tried to tighten the leg together with it like that. Crack that lower leg housing, and you may as well start looking for a new motor, I'd bet.