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1995 Merc two stroke lower unit issue

T

TritonFisher

Regular Contributor
Hi all,
I have a 95 Merc 60 two stroke that recently had the impeller changed. When the engine is running in neutral in the water, there is a clicking noise that I do not remember being there before.

With the engine off, the propeller rotates freely in either direction. No noticeable noises.

With lower unit off, the shift into f or r is free and easy.

With the engine running and in the water, easy shift into f but harder into r.

I’ve taken the lower unit off and reinstalled to see if it was just not synced up. This was done in neutral. Should I remove and reinstall in forward?

Any ideas?
 
Try adjusting the shift cable, the clutch dog maybe just barely rotating closely to the gear face when running; causing the clicking noise. Disconnect the shift cable, shift into neutral by hand and start the engine, shift the engine through gear selection. Do this from inside the boat or make damn sure you know where your legs and feet are around a spinning propeller. If the clicking goes away, adjust the shift cable to match where the shift pin is, with a very slight pre-load to reverse. If the issue comes back, replace the shift cable.
 
TritonFisher said:
Thank you. I’ll give this a shot this afternoon or tomorrow and report back.
Click to expand...
Since you'll be adjusting the shift cable, you can also check the throttle cable pre-load against the idle stop which can also add to shifting difficulties. To have the idle stop adjusted properly. ( this assumes you're happy with the idle speed). Disconnect the throttle cable where it adjusts. Place a strip of notebook paper between the idle stop and the boss that it bottoms out on. reconnect the throttle cable. Try to pull the paper out of the the pinch. If the paper tears the preload is too tight, adjust the throttle cable (not the idle stop screw) to where is a slight tension on the paper without tearing it. Basically, the reason for this is that if the preload is too tight, it hinders the full engagement of the detent in the control box to allow it to be shifted smoothly.
 
Well—disconnected the shifter cable assembly and started it in neutral. Very easy to move by hand into forward but not happening in reverse. Something is definitely not right with it!
 
TritonFisher said:
Well—disconnected the shifter cable assembly and started it in neutral. Very easy to move by hand into forward but not happening in reverse. Something is definitely not right with it!
Click to expand...
Edit—still tough to get into reverse but easier than before. I did the paper test mentioned above and that was spot on. Time to fish!
 
Have you tried shifting the engine by hand with the lower unit off? You said the gearcase shifts fine when unbolted from the engine. Maybe binding in the midsection somewhere. If this was a manual tilt model, then it could be the reverse lock linkage. This is a ELPTO model?
 
This is an ELPTO model. The engine shifts great with the lower unit removed. When testing my new cheap rpm gauge today, it sounded like it wanted to let itself go into gear, causing the engine to turn off.

I eventually played with the shifter at the helm to make sure it was in neutral and was all good to run for a bit.

I’m getting close to having a pro do this quick for me though!
 
These engines are spring loaded to shift into forward gear, reverse has much more resistance to shift. I would say 50% more effort. So don't throw the baby out with the bath water. There maybe nothing wrong with this unit. With the extra effort, does it go into reverse and stay there without grinding or noise? Did the clicking go away in neutral? what does the magnet look like on the bottom drain screw? Any large metal fines or just gray goo? Is the gearoil clean? Is this engine a Bigfoot or standard gearcase?
 
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This is the standard gear case and the oil was spotless with nothing in the drain plug. The receipt for the drain/refill was from 2023 and was used all of 2024 before I bought it this year. I changed it just in case and it was perfect.

That’s good to know about spring loaded. That makes more sense on how it feels to shift it. All I have to go on is my experience with the larger Honda outboard and smaller Merc.

Total side note—I’m shocked how quiet this thing is on the water for a two stroke!
 
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