Finally got my engine mated, got my outdrive mostly installed, but I'm getting hung up by not being able to rotate the hinge pins so the locking bolt can ride down inside...
Are you trying to install a complete drive..... i.e., transmission, Intermediate housing and lower unit as an assembly?
If so, I would suggest installing the Intermediate housing and lower gear unit ONLY!
Install transmission last!
I have a massive semi truck screwdriver to try and rotate it the 1/8" I need, but it just simply will not budge (in have anti seize on the pins as well).
Automotive Anti-Seez will turn into Always-Seez in a wet environment.
Instead, use a water proof grease.
Questions:
How were the suspension fork hinge pins removed?
Was a steel drift punch used?
Did either pin become expanded during removal with a steel drift punch?
(always use an aluminum or brass punch)
Is there some other alternative or a way to get these little buggers to line up correctly?
If a steel drift punch was used to remove them, you may have expanded these very soft hinge pins. It doesn't take much expansion to make them difficult to remove or to replace!
If so, pull them back out and mic the diameter looking for expanded areas.
If they are expanded (they most likely are), then gently roll them against a bench style disc sander (equipped with fine paper), taking off only a few ten thousandths or so.
Re-fit them into the aluminum bores.
When greased, they should slide in/out of the bores fairly easily.