mercruiser 165 - stalls on return to dock

[tony dz]

My 1978 mercruiser 165 inline 6 seems to always stall as i'm coming back into dock. It will restart, but immediatly stall as I shift into gear (forward or reverse). It has stalled on the way out too, but seem much worse on the way back. I suspect running it slow in the no wake zone maybe a contributor, but again I don't notice as much on the way out. <br /><br />I've just replaced points, condensor, cap, rotor, and coil. But the problem was also happening before I replaced them<br /><br />I do have the idle set a bit high ~1000rpm.<br /><br />Could this be a fuel mixture issue or is there somthing else I should be looking at?

 

[Bt Doctur]

Re: mercruiser 165 - stalls on return to dock

sounds like the shift cable is bad or some corrosion in the shift mech.,plus the idle is too high.if you shift out of gear and the switch is activated it will stall the motor if the cable is binding up.works only coming out of gear by putting a momentary miss in the engine to help the clutch dogs release.

 

[tony dz]

Re: mercruiser 165 - stalls on return to dock

is there anything I can test to check this out? <br /><br />The shifter feels smooth. would it feel like it was binding if this was my issue?

 

[tony dz]

Re: mercruiser 165 - stalls on return to dock

another thought.. if it were cable/shifter.. does the fact that it mainly happens on the way back (i.e. after a long idle through no wake) make sense?

 

[imported_Dave_C]

Re: mercruiser 165 - stalls on return to dock

Originally posted by Bt Doctur:<br /> sounds like the shift cable is bad or some corrosion in the shift mech.,plus the idle is too high.if you shift out of gear and the switch is activated it will stall the motor if the cable is binding up.works only coming out of gear by putting a momentary miss in the engine to help the clutch dogs release.

Did Mercruiser use that system in 1978 ? I thought only OMC did that.

 

[Haut Medoc]

Re: mercruiser 165 - stalls on return to dock

Not really, but...<br />Lube the pivot points on the shift plate assy, including the shift cut-out switch....<br />I suppose heat could make them tighter after use....<br />How old is the cable?<br />You probably need to do both.....<br />Try oil first, though not WD 40, but Kroil or pb blaster or 30 weight....<br />If that doesn't work, change the lower shift cable......JK

 

[tony dz]

Re: mercruiser 165 - stalls on return to dock

the cable is old, probably original (1978). I'll check and lube today.<br /><br />Any thoughts on my carb guess? i.e. can I rule out the carb on this one or is that a posibility?

 

[bamadave]

Re: mercruiser 165 - stalls on return to dock

Why do you have idle set to 1000 rpm? Do you have it set that high to keep the engine running?<br />How long has it been since a carb rebuild?

 

[bamadave]

Re: mercruiser 165 - stalls on return to dock

Why do you have idle set to 1000 rpm? Do you have it set that high to keep the engine running?<br />How long has it been since a carb rebuild?

 

[tony dz]

Re: mercruiser 165 - stalls on return to dock

First time I started it it was a little rough at first (it had sat for 2yrs)and I thought 600-700 was too low so I adjusted it up. Now I've realized it's too high and will adjust it down this morning and I'm taking her out today. <br /><br />Carb hasn't been rebuilt for a long time (if ever). <br /><br />I just pulled the cover and looked at the shift assy.. where is the shift cut out switch? I see an electronic switch that I assume is the neutral switch... this isn't the same thing is it?

 

[tony dz]

Re: mercruiser 165 - stalls on return to dock

Think you guys are right on.. I'm always amazed at the good tips I get here.. Strangley when I started it just now on the trailer.. it would go into reverse, but immediately stall in forward. (hadn't done this on land before).. anyhow I played with the shifter assy to figure out how it should work and noticed the switch was poping nicely into position in reverse, but wasn only rolling half half-way up the cam in forward. Anyhow, lubed the pivots and adjusted the lower cable by rotating the cylider shaped cable anchor a few turns and it seems to be working now. Taking her on the water today, let's hope it holds up, but at least I know where to tinker now. <br /><br />So what does this mean. Is this type of adjustment, "normal" or do I have a bad cable or cable going bad?<br /><br /><br /> noticed

 

[ziggy]

Re: mercruiser 165 - stalls on return to dock

heres a link for ya that may help ya. its specs for prealpha adj. of the shift cable. i suppose that's what ya have. a pre alph a that is. <br /><br /> http://www.mercstuff.com/images/shiftcable.jpg <br /><br />like eveyone says, cable may be bad, but then again, ya just might need to adj. it. i think ya need to adj. it under load in the water too. i failed in settin mine up and had the dealer do it. thought i had a bad cable. turns out he adj. it in a tank. and that worked good. i agree, yer idle need to come down too. good luck..

 

[FreeBeeTony]

Re: mercruiser 165 - stalls on return to dock

Hey ziggy.....how's the IL6?

 

[Bt Doctur]

Re: mercruiser 165 - stalls on return to dock

considering it1s NOT supposed to move going in gear only coming out of gear.<br />"assy to figure out how it should work and noticed the switch was poping nicely into position in reverse, but wasn only rolling half half-way up the cam in forward."

 

[tony dz]

Re: mercruiser 165 - stalls on return to dock

Update: what seemed like a good idea wasn't.. I took it out today and ran great for about an hour.. starts stops, reverse forward no problem.. shut down for a about 30 minutes and when to restart and it woulnd't start.. noticed the shift switch was wasn't in the neutral position. I manually pushed the switch into neutral and she fired up, but I couldn't shift into gear without stalling.. after being towed back to dock, I'm back looking for advice. <br /><br />Ziggy thanks for the drawing.. I do have pre-alpa. I'll try this tip.<br /><br />Bt Doctur, can you explain how it should work.. this is what I saw before I made any adjustments.. there is a v shaped cam that engages the shift cut-out swith. In neutral the switch sat in the bottom of the v. when shifting into reverse it rolled up to the top of one side of the v and when shifting into forward it rolled only half-way up the other side of the v. I assumed it was supposed to roll to the top of each side so I adjusted the cam cylinder to get it rolling up both sides equally.. after I did this it was shifting into forward or reverse fine on land w/ muffs... and for the first hour on the water.. <br /><br />Oh, and by the way I adjusted the RPMs down to about 700-800.

 

[tony dz]

Re: mercruiser 165 - stalls on return to dock

clarification.. i adjusted the brass barrel, not cam cylinder while on land

 

[Bt Doctur]

Re: mercruiser 165 - stalls on return to dock

Like i said, it works only coming out of gear ,should not move at all going in gear. on land there is no resistance from the prop cause its in air .to shift the motor need this miss/ stall from the switch to unload the torque thats on the clutch dogs.only other way for the switch to operate going in gear is if the total throw is way off.the stud that the shift cable attaches to has a vertical slot for adjustment.remove the cable from the stud and move it by hand in and out . it should move freely,nice and easy.any binding will need to be investigated.an over heat will damage the cable if it passes near the exaust tube.water entered the cable causing the outer wire casing to swell from rust and cause a binding.

 

[daniel295261]

Re: mercruiser 165 - stalls on return to dock

Ahoy seasoned mariners!

I am having difficulty identifying the correct replacement part number for my lower shift cable.

I just purchased a 1978 Century Boats Century 180 with an inline 6 engine and a mercruiser 165 outdrive. I was having a heck of a time shifting. First I disconnected the remote shift cable at the transom plate and the control cables (at the remote) shifted quite smoothly. Hence I ruled-out a control box/control cable issue.

Next, I tried to move the transom plate by hand and it really took some elbow grease to move. It appears the engine cutoff switch (described in this thread) is working normally . . . although there is no load on the prop and the engine is off.

The service manual I have for the outdrive agrees with the suggestions above that my lower shift cable has become broken or corroded. I presume this is due to the previous owner using the boat as a "leaf collector" for the last 5 years.

I have yet to remove the upper and lower units as I am having some difficulty identifying the correct lower shift cable to purchase for replacement. I have found perhaps a dozen "new" style cables that are indicated for this outdrive, but I am not convinced any of these are the correct cables (or cable kits). Once I have located the correct lower shift cable, I intend on replacing the cable, the shift cable bellow and probably the exhaust bellow just to be sure there is no leakage through the transom.

Any idea what my OEM part number is for the lower shift cable or where I can obtain the proper replacement for the Mercruiser 165 with the serial number below?

 

[silvano]

Re: Merc 5.7 thinks its a car HELP!!!!!!!!!!!

Re: Merc 5.7 thinks its a car HELP!!!!!!!!!!!

Hello all i am new to this site and new to boating. Here is my weird problem last week i just bought this boat its a 26' ft cruisers merc 5.7 alpha one drive took it out to a local lake but before i went to the lake i made sure the boat would start so i hooked up my hose and ran it for about 5 min then i hooked up and left to the lake when i got there i backed down the ramp and it started then stalled i open the choke i thought maybe i flooded it still crank no start then pulled it out and quess what it started up then quickley shut it down so im back in line waiting my turn to unload get to the ramp back it down starts up and the same crap happens this time i crancked it till the dam battery die's lucky for me there was a marina up the road. bought a new battery popped it in and started again on land grrrrrrrrrrrrrrr. So here i am 3 hours trying to get this boat in the water so this time im on the ramp i start it before i get in the water back it down while its running im in the water had it reved up to around 1500 rpm stayed on the ramp till the temp rised a bit. Now the boat is finally in the water drove it all day (7) hours no problem. Now do i have a boat that thinks it a car? lol Y does it start on land and problems while its in the water also when i put it reverse it sometimes stalls.

Thank you all

 

[md165250]

Re: mercruiser 165 - stalls on return to NEUTRAL

Re: mercruiser 165 - stalls on return to NEUTRAL

Oh wow I am so grateful to find this thread! I have mcruiser 165 that runs perfectly at idle,troll,cruise,and wide open,and pulls skiers strong. i have been tormented by this problem of engine cutout when returning to neutral and then not cranking until I jiggle the control lever. When the jiggle restores ingition VROOOOOM, starts abruptly. In the troubleshoot process I disabled the 'NO CRANK IN GEAR' wire and intend to reinstall this safety feature. From the threads I have determined as best I can that it is definitely in the shift interupter cut out switch. I have been tormented by this otherwise perfectly running mercruiser with low miles. Can the shift cable get hot and cause this? Where is the switch for me to replace? Thanks to all for this forum.:confused about how to find and replace the shift interupter: