cant switch older (1980) 15 hp into reverse

[Lineaxe]

Hi , We are working on a 1980 15 HP evinrude 2 stroke. We are having problems attaching the leg again since the gap is so tight that we can barely squeeze a screwdriver in. When we reconnected it , we can't change shift into reverse , but the forward and neutral are changing. ie the arm length isn't long enough to push it into reverse. Before we take it apart again we would appreciate any advice from others who have worked on this or similar evinrudes.

 

[flyingscott]

Are you turning the prop when you try and shift it. If yes and it still wont shift then follow the instructions.
Do this Take it back apart.
Now turn the lower shift rod into the lower unit until it is tight make sure the brass clamp is on that one.
Now back it out ONLY enough to line up with the upper shift rod. Roughly a 1/4 turn
Now pull the lower shift rod up as far as it will go ( you may need to turn the prop to get it to catch)
Now use the shift lever on the motor to bring the upper rod as low as it will go.
This will give you enough room to connect the 2 rods.
When you assemble the shift rod make sure the groove in the rod lines up with the bolt in the clamp.
When it is all assembled you can use the gear shift on the motor to GENTLY pull the 2 pieces together

 

[oldboat1]

Sorry -- sounds like it might have to come apart again. Have to make sure each of the screws/bolts runs through the machined openings in the end of the upper and lower shafts. If not, the overall length will be affected (close tolerance), and the motor will not shift properly. It's a good idea to open up the brass connector slightly with a bladed screwdriver, just to make sure the rod can slip in freely. (Problem is the connector will clam onto the rod end(s) and fool you into thinking it's hooked up properly)

But, I'll assume the bottom screw in your link is attached properly. See if you can ease the gearcase or g.c.extension bolts out a bit further to give you more room. Put the gearshift lever in whatever position moves the upper rod down (likely reverse). Reach in with a bladed screwdriver and try to lift the lower rod up a bit by hooking the connector. Adjust the upper rod height with the shift lever until just above the connector, then slip the rod down in the opening (may need to use a needle nose pliers to help with the line up). Hopefully, you've managed to leave enough room to install the screw/bolt. If you drop it down into the leg, of course, the gearcase has to come off and tipped over to dump out the screw!

Sometimes they go together with no trouble at all. (Sometimes not.)