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Boat wont start after lower unit was off for impeller replacement

J

justputtering

New member
Replaced impeller, reassembled lower unit. When I tried to start it, it turned over a couple times then nothing. Wont turn over at all. Seems like it is in drive, not neutral, could the gear spline and coupling have come apart or not lined up. possibly it is in gear so the safety switch wont let it start?

1990 searay with first gen motor and alpha one. 5.7 liter
 
Move the throttle handle fwd/Rev slightly while holding key in start position to see if starter engages

The neutral safety switch is in the throttle handle
 
Remounted the lower units, seems to be in neutral now. Will not turn over at all. I havened looked at the neutral safety switch yet, but neve had an issue before. Is there an adjustment?
 
Need a voltmeter
Start at key and see if 12V can be found on the Red/Yellow wire when key turned to start

If 12V is there, find slave relay on motor. It will have 2 larger wires (red/purple and Yellow/Red) on top terminals, Will also have 2 small wires (Yellow/Red and Black) on bottom terminals.

Turn key to start and see if 12V is found on the smaller yel/Red wire

If 12V is found take something and jump across top 2 larger wire terminals. Starter should engage
 
Ok played around with throttle and got the boat to start in neutral normally. Went to put in rev or forward and there is clashing gears.... It there a way to index the gears and or shift gearing? Already had lower of a few times so starting from scratch.
 
justputtering said:
Ok played around with throttle and got the boat to start in neutral normally. Went to put in rev or forward and there is clashing gears.... It there a way to index the gears and or shift gearing? Already had lower of a few times so starting from scratch.
Click to expand...
When you put the two hales of the drive together on a gen one the shift shoe in the upper needs to be facing forward and the splines shift shaft in lower needs to be fully CW to also be in forward. These may be mis-indexed. If that wasnt done start there.

Also with a dog clutch as AD mentions you need to shift firmly and quickly into gear. a clunk is normal, almost like shifting a stick shift car with out using a clutch. If you dont do it quickly it it will grind
 
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