Yanmar gear shift problem

[bluey]

I posted this question on two other forums but had no replies, so now it's over to you guys.

I recently reinstalled My 2qm15 Yanmar engine during a boat restoration project. This model has the KBW10 gearbox and I'm having real problems shifting into Neutral after selecting Forward or Reverse. This problem is definitely with the shift lever which is located on the side of the gearbox and is operated by a Morse 33c cable.

The gearbox clicks into gear ok but is very, very stiff when trying to select neutral. When the shift lever is disconnected from the cable, the gears can be easily selected by hand but it's very tight trying to get back into Neutral. When the cable is connected to the shift lever it is even worse. it's really so stiff I am worried about breaking the handle on the Morse control lever.

My throttle/gear control is the Teleflex MV-2 Morse type which I fully serviced and rejuvenated before re-installing. I also replaced the original morse cables with brand new ones and there are no tight bends so I know the cables are not contributing to the problem.

Before I installed the engine I serviced the geabox by flushing it with kerosene and oil and have since filled it with the correct new oil as specified by Yanmar.

Does anyone know what I can do to solve this problem, please?

bluey.

 

[alldodge]

Re: Yanmar gear shift problem

When your going to netural you are back at specified idle rpm correct?
What lubricant is in the trans?
Is shift point distance from netural to forward and netural to reverse the exact same distance?

 

[alldodge]

Re: Yanmar gear shift problem

Upon further review, your shift length needs to be 1.5 inches for forward and 1.5 inch for reverse. The Morse control states it provides 2.75 and 3 inch shift through, this is an issue according to Yanmar buliten AOA 1003.

 

[bluey]

Re: Yanmar gear shift problem

Thanks for the reply AllDodge,

Engine idle rpm is correct.
Lubricant used is Auto Transmission Fluid as recommended in the service manual
I may not have the linkages adjusted quite right, I'll have to recheck.

I've googled for that Yanmar bulletin AOA 1003 but can't find. Any ideas where I might get one?

 

[bluey]

Re: Yanmar gear shift problem

Thanks for the reply AllDodge,

Engine idle rpm is correct.
Lubricant used is Auto Transmission Fluid as recommended in the service manual
I may not have the linkages adjusted quite right, I'll have to recheck.

I've googled for that Yanmar bulletin AOA 1003 but can't find. Any ideas where I might get one?

 

[alldodge]

Re: Yanmar gear shift problem

I have been unable to find it my self, just found it mentioned in other searches. Just to be up frount, I'm not an expert with Yanmar just an old guy that has been wrenching for many years and likes to research problems. The manual I been reading indicates the shift movement should be 1.38in (35mm) and ATF is type A.
ATF - A Description - Kroon-Oil Gear Oils Car/ Light transport - Catalogue - Kroon-Oil

With all of the tight tollerancing being outlined in the manual kind of wonder if a two lever system would be better suited. With the trans being able to be shifted with less difficulity then with the shifter attached leads me to this area. My manual indicates a 7.9in (200mm) minium radius and have a minimum stright travel to the shift control a minium of 4in (100mm).