80-81 Merc 9.8 Long shaft hard to get into forward

[rockb]

Just picked up an 80-81 Merc 9.8. It will go into reverse without any problems. If I pull forward on the shift lever pretty hard it will engage the prop in forward but I have to hold pressure on the lever or it will slip out. I figured there would be some kind of linkage that could be adjusted but it looks like a straight shaft from the lever into a gear that shifts. Then I took a look and there is a thin rod that slides up and down as I move the shift lever but it looks bent. It also a lot thinner than what I would expect to do this job.

Is there supposed to be something covering that rod?

 

[Mi duckdown]

Re: 80-81 Merc 9.8 Long shaft hard to get into forward

Has nothing to do shifting. that is to realease the motor in foward gear when you hit something.
serial number would help? I think? where is the pin to adjust the motor angle and clamp screw?

 

[rockb]

Re: 80-81 Merc 9.8 Long shaft hard to get into forward

5823693

 

[carholme]

Re: 80-81 Merc 9.8 Long shaft hard to get into forward

MERCURY - ( 9.8 H.P. (1980 ))
Serial No: 05823693 Model No: 1010220

Parts list for model 1010220:

Mercury Parts, 7.5 /9.8 H.P.

See under BOTTOM COWL AND SHIFT LINKAGE for the upper side of the shift arrangement and where it mates with the lower side under GEAR HOUSING (PROPELLER SHAFT)

Probably just as easy at this time to drop the LU and see if tiller shift operates freely and test the shift range of the LU by rotating the LU shift shaft.

Gerry

 

[rockb]

Re: 80-81 Merc 9.8 Long shaft hard to get into forward

MERCURY - ( 9.8 H.P. (1980 ))
Serial No: 05823693 Model No: 1010220

Parts list for model 1010220:

Mercury Parts, 7.5 /9.8 H.P.

See under BOTTOM COWL AND SHIFT LINKAGE for the upper side of the shift arrangement and where it mates with the lower side under GEAR HOUSING (PROPELLER SHAFT)

Probably just as easy at this time to drop the LU and see if tiller shift operates freely and test the shift range of the LU by rotating the LU shift shaft.

Gerry

Thanks Gerry,

Do I need to drain the LU oil prior to dropping it?

To drop it is it just the 1 bolt under the cavitation plate above the prop and the 1 nut at the front of the engine that goes onto stud 2 in the Gear Housing - Drive Shaft pic at the link you provided?

 

[carholme]

Re: 80-81 Merc 9.8 Long shaft hard to get into forward

No need to drop the oil but if you find shifting difficulties when you have it separated from the engine, you definitely should drain it then to check for any metal particles, indicating severe wear or damage. Once you have the oil drained in to a container, you can pass a magnet through it to see what it picks up.

Yes for the bolts/studs.

Service manual for your engine is p/n: 90-86136--1

http://www.ebay.com/itm/USED-93-Mercury-Outboard-4GNAT-2-Cyl-Service-Manual-/270801861770

Gerry

 

[rockb]

Re: 80-81 Merc 9.8 Long shaft hard to get into forward

OK I get the I D 10 T award for the month. The shift lever was hitting the hose clamp holding the fuel line on.:lol:

Got that resolved and got the foot dropped to take a look at the impeller. Got it off and there was not one vane left on it. I got it out but with no vanes left I have no idea which way to bend the vanes on the new one when I put it in. Looking from the top, which way does the shaft run: clockwise or counter clockwise?

Now that I have the foot off how in the world do you get the copper water tube lined up with the head? Is it supposed to be bent like that?

 

[carholme]

Re: 80-81 Merc 9.8 Long shaft hard to get into forward

Well, at least you seem to have the shifting problem sorted. Have you verified that the LU is shifting OK?

The driveshaft will turn CW as viewed from the top. As the old impeller has lost all of it's vanes, the question is, are some of them still in the engine?

Yes, the water tube is shaped that way. See item 8 under DRIVE SHAFT HOUSING ASSEMBLY. If you look up inside the housing you will see the two holes at the lower end of the engine where the driveshaft splines in and where the water tube fits. First, closely examine the hole where the water tube fits and see if you can see any pieces of the lost impeller vanes blocking the water inlet to the engine.

If there is nothing there, you can re-assemble the engine and see if you are lucky and that there are no old pieces of impeller vane stuck in the internal passageways of the engine, impeding water flow. If it were my engine, I would start confirming the internal passageways by removing items 29/27 under CYLINDER BLOCK AND CRANKCASE and ensuring that there is nothing in there to block water flow. If you blow up the diagram you will see the passageways in item 8. Also mounted on top of item 8 may be a thermostat, some engines had them and some didn't. Remove the cover and see how yours is if there is one installed. There is a risk of breaking some of the bolts, item 30 if they have not been removed in a long time, so be careful.

Let us know which way you are going to go and what results you find.

Gerry

 

[rockb]

Re: 80-81 Merc 9.8 Long shaft hard to get into forward

There were a couple of pieces of the vanes in the bottom of the pump housing assembly but I will try checking the internal passageways. Hopefully none of the bolts break.

 

[rockb]

Re: 80-81 Merc 9.8 Long shaft hard to get into forward

Let us know which way you are going to go and what results you find.

Got the new impeller put in and got the foot back on. Had no Idea how to tell if the copper tubing had gone into the slot or not. I was going to come in and ask about that. Then I took off the plate to look for vanes that may have gotten in. Then I answered my question. The copper tube had missed the slot by a couple of inches.

With the plate off I had plenty of room to get in where it needed to go. Looks pretty bad in there oil everywhere. Is that normal?

 

[txbandit44]

Re: 80-81 Merc 9.8 Long shaft hard to get into forward

Pretty sure this is normal you are looking at the exhaust side of the motor.

So did we determine that the skinny rod (reverse lock) is not needed?

 

[oldman570]

Re: 80-81 Merc 9.8 Long shaft hard to get into forward

The burnt oil gas will leave a buildup as you have. It could be that the oil mix to gas was some more than needed and will not hurt a thing othewr than fouling out plugs if fuel mixture is the same. A good decarbing of the motor should be done and the use of Sea Foam every now and then will help keep the carbon buildup down some. I use Power Tune, bought at local Merc dealer, for decarbing and cleaning up the motors that I have. It works great following the directions on the can. Remove the plugs and spray the inside of the cyclenders and piston tops as well.
The reverse rod is needed and some bend is normal for them. The tilt pin is needed for the reverse lock to work also as the lock catch has to hook over it to hold the motor down when in reverse. JMO
Oldman570

 

[rockb]

Re: 80-81 Merc 9.8 Long shaft hard to get into forward

Got it all back together. Runs and shifts fine. Now I have to deal with the carb leaking furl like crazy. Have to track down all the gaskets and replace.

 

[oldman570]

Re: 80-81 Merc 9.8 Long shaft hard to get into forward

The float level could be set to high, or the inlet needle and seat are not sealing, as they should when the float is set correct. You can test everything by using a tank and fuel hose, while the carb is on the bench, to make sure it is set good. Just hook the tank and hose to the carb with a hose clamp and pump the primer bulb up, as you would if it was on the motor, to save time takeing it on and off the motor. JMO
Oldman570

 

[rockb]

Re: 80-81 Merc 9.8 Long shaft hard to get into forward

The float level could be set to high, or the inlet needle and seat are not sealing, as they should when the float is set correct. You can test everything by using a tank and fuel hose, while the carb is on the bench, to make sure it is set good. Just hook the tank and hose to the carb with a hose clamp and pump the primer bulb up, as you would if it was on the motor, to save time takeing it on and off the motor. JMO
Oldman570

Thanks for the suggestion of troubleshooting it while it was off of the motor. That was helpful.

I pulled the carb off and removed the bowl. If I blow into the fuel inlet then raise the float I am not able to blow through it so I figure that the inlet needle is sealing. Don't see any way to adjust the float. I think I just need to find somewhere to find the gasket that goes in between the bowl and the carb. None of the parts places seem to have it listed. Don't even have a part number for me to search on.

 

[Maxz695]

Re: 80-81 Merc 9.8 Long shaft hard to get into forward

Don,t know if this is what you need please check for compatibility 1972 1985 9.8 HP Carburetor Gasket Kit Mercury 7 5 9 8 20 45 50 HP 1399 5135 5198 18 7007 | eBay

 

[rockb]

Re: 80-81 Merc 9.8 Long shaft hard to get into forward

Don,t know if this is what you need please check for compatibility 1972 1985 9.8 HP Carburetor Gasket Kit Mercury 7 5 9 8 20 45 50 HP 1399 5135 5198 18 7007 | eBay

That will do it but I only need 3 of the parts

 

[rockb]

Re: 80-81 Merc 9.8 Long shaft hard to get into forward

Got the kit. Now not sure if it is the right thing. The parts diagram looks like two orings that should be identical ( No. 12) but the kit doesn't have two identical parts in it that come close to matching.

 

[oldman570]

Re: 80-81 Merc 9.8 Long shaft hard to get into forward

I belive that the small flat red colored washer and the small rubber O ring are the ones that fit item 11 in the diagram. The red one should be on the outside of the bowl when installed and these seal the bowl from leaking. There should be a small tab on the float than might need to be bent and adjusted to set the feul float level. JMO
Oldman570

 

[rockb]

Re: 80-81 Merc 9.8 Long shaft hard to get into forward

The brass ring (bottom of the bowl gasket in the kit pic) fit directly in the pickup (the top number 12) and the polimer looking flat washer (to the left in the bowl gasket in the kit pic) fit around the bolt that holds the bowl on. Seems to be fine just pumping the ball. Will run it on Sunday and see how it goes.