Dingy 3.5 hp outboard will not shift into forward

[rortega46]

I have a 3.5 hp Mercury/Tohatsu dinghy outboard. Upon changing the impeller, I accidentally opened up the lower unit chamber. I successfully reattached the lower unit to the engine, but now it will not shift into forward. I don’t think it’s a linkage adjustment because after detaching the lower unit a second time , the propeller would not engage gears when manually lifting on the Lower unit linkage. Does anyone have suggestions regarding how to fix this problem?

 

[justsomeguy]

Got a manual?

OWNER'S MANUALS | TECHNICAL INFORMATION | TOHATSU International

Download the Owner's Manual for Tohatsu Outboard Motors.

www.tohatsu.com

 

[NYSail]

Weee you having nag issues with impeller? When changing the impeller, just change the impeller. Bring it to a shop.

 

[rortega46]

Justsomeguy....I have an owners manual but need a shop/service manual.

NYSail...It shouldnt be so difficult to change an impeller, but Murphy struck and here I am. I was just looking for advice from someone who has experience servicing their dinghy motor. Last resort will be bringing it to a shop and pay 1/3rd the cost of the motor to have someone fix it.

 

[justsomeguy]

Justsomeguy....I have an owners manual but need a shop/service manual.

D'oh! Mea culpa.

 

[Rich Stidger]

D'oh! Mea culpa.

Here is a parts manual with exploded drawings. I don't have a real shop manual that explains step-by-step how to repair. This is for the Nissan 2.5-3.5 engines but it should be nearly the same for your engine.

 

[Rich Stidger]

I have changed the impeller on my 3.5hp outboard without any issues. However, I have had the shift linkage be mis-adjusted and it caused shifting problems. I know you said that with the lower unit off and lifting on the shift rod it still would not engage, but I don't know what else to suggest. Sorry....

 

[jonelli]

Are you sure you re-connected the shift rod? I know that when you remove the lower unit, there several tubes and rods that have to be lined up and reattached. You need a coat hanger to line them up sometimes.
But, here is the service manual that has pretty good instructions on the assembly and disassembly of it.

 

[rortega46]

Rich Stidger...I guess I’ll try taking the lower unit apart again and reassemble.

jonelli...the Tohatsu service manual is exactly what I was looking for. Thanks! It has good details and will be helpful.

 

[Rich Stidger]

But, here is the service manual that has pretty good instructions on the assembly and disassembly of it.

Thanks for the service manual. I never had a copy.

 

[jonelli]

Thanks for the service manual. I never had a copy.

You are welcome. Someone else here came through for me, so just doing my part to share back.

 

[Project_Mayhem]

I used zip ties to align the rods on my 4hp Tohatsu. Good luck! Keep us posted!