Lower unit mating/shifting problem - Need some help

[goinsfishin]

Need some help or advice on an 89 Yamaha 200??replaced my water pump impeller about a month ago with my stepson assisting?..I?ve probably done a hundred of these over the years so no problem??finally got around to test running the engine today and found no reverse. Pulled the LU and reset the upper and lower shift splines while in neutral?..now no forward?..the upper spline and lower spline wont mate right with both in neutral and can?t get the case to seal?.about a 1/2? gap. If I turn the lower shaft slightly in either direction it slides right together but the upper shaft dog is now too far into forward or reverse and don?t have the opposite gear??I suspect my stepson accidentally turned one of the shafts but now I can?t get it back together right.
I?ve disconnected the shift cable entirely and am using the shaft dog to align the upper shift shaft and still have the same issue. I have also tried aligning while in forward and in reverse?.still is off by a fraction of a turn but enough to prevent full shift motion.
Been messing with this thing for hours now and keep getting the same results.
Have never run into this before.
Any ideas ?

 

[natespapa]

Re: Lower unit mating/shifting problem - Need some help

Goodmorning,So glad you wrote this post.I have a 1988 suzuki 65 and i'am haveing the same problem.Like your self i've done it a hundred times and this is the first time this has happened.If you get a answer please let me know, and i will do the same.Natespapa.

 

[UpforAllnight]

Re: Lower unit mating/shifting problem - Need some help

Guys just wondering, did it shift before you took it apart?
I had some trouble with shifting before only to find out some water froze in the lower unit pushing things just out of place. No real damage was done, but I could not adjust and pickup reverse.

Good luck finding the answer

 

[flounderman]

Re: Lower unit mating/shifting problem - Need some help

Before your Stepson gets depressed and runs away from home, there is a chance that the shift shaft could have twisted and this is no fault of his. If it is a saltwater motor the shaft that goes thru the pivot tube rusted and became weak. I had to replace mine this past winter. The new ones are stainless. Hold the coupler end with your fingers and see if it bends or twists. There are posts concerning this issue, do a search. Good luck. Ps. I am a Stepson and I didn't do it, it ain't my fault.