Re: super seahorse shifter lever
If the bolt that holds the lower shift shaft is there, then the shift shaft was not inserted fully into the connector. Carefully remove the bolt, then make certain the groove in the shift shaft lines up with the hole in the connector and re-insert the bolt and tighten (not too tight, you don't want to strip the threads).
If the bolt isn't there, it's probably stripped, since that's very common. Either the bolt gets stripped or the rear threads in the connector get stripped. In that case, you can get a replacement connector and bolts.
There is a way to repair this, but it's a bit involved:
Shift Shaft Connector Repair
Trouble is with the long shaft conversions on the Big Twins, the shift shaft connector is 5" longer, it's not at all cheap to replace, although the part is available.
Stripped threads on those connectors is quite common. Of course, the proper thing to do is to replace the connector. They're still available as new parts. If you have a long shaft motor, you're going to be shocked at how much that 6" long piece of brass costs, though, and replacement on the long version requires some very serious disassembly of the outboard.
Short shaft shift shaft connector: 0303794 Price about $16.50
Long shaft shift shaft connector: 0304081 Price about $70.00
You can order them at any Evinrude dealer or on the net at:
http://shop2.evinrude.com/ext/index....cfd8a6471c0f7f
Alternative:
I did fix one that stripped this way. You do it at your own risk, though:
1. With lower unit off, drill the rear hole in the connector (where the threads were) out to 1/4", removing all the threads.
2. Drill the outer hole in the connector to 5/16", being careful not to drill the back side.
3. Tap the rear hole with a 5/16" tap. Lubricate well, because taps like to stick in brass.
4. With a dremel and a 5/16" diameter round stone, carefully enlarge the groove on the shift shaft to just a 5/16" profile. Don't remove any more metal than you absolutely must! Frankly, I just did the side of the shift shaft where the bolt would pass by.
4. Re-install the lower unit and make very, very sure the groove lines up with the hole before re-inserting a proper length 5/16" cap screw. (Note: you can find 5/16" cap screws with a 7/16" hex head at auto parts stores. This makes it easier)
Always be careful after doing this. Don't overtighten and strip the threads. You've gone as large as you can go.
Again, this is not the official way to do this repair. It worked on mine, and the fix lasted for a long long time, and was that way when I sold the outboard.
