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Mercury 25XD 1986

S

shanny871

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Can anyone help with disassembling the twist grip from the tiller arm on this 25XD? I want to replace the stop switch on the end of the tiller arm at the twist grip. I have removed the rubber grip to expose the set screw and removed the set screw but cannot get any further without totally wrenching too hard. It does not seem to want to move, am I missing a step?
 
Time and chemicals is the answer. It looks like it is a two piece switch can you just take the button off and clean the contacts? If the wires are still good you should be able to kill it just shorting the contacts?
 
That's the thing, I believe the twist grip has to come off before I can take the rubber cover for the contacts off. I feel like if I can get the twist grip off, the job would be much easier but I can't get it off without really tugging hard on it, which I do not want to do. I don't know why the set screw is on there if it doesn't do anything though.
 
You can try heating it with a torch just dont get it too hot to melt the wires. Can you just pull the wires through the handle by pulling on the switch? It looks the grip is what holds the switch in?
 
The rubber grip will peel off. Start at the back by the throttle lock and gently pry up with a screw driver and work it around pull forward on the grip at the same time. Be careful not to break the plastic underneath it. Once you have it started it will slide off of the front pretty easily. Underneath there is the screw that holds the plastic piece to the shaft remove that. Then remove the access panel at the back of the tiller 3 screws hold it in. Opposite of that by the big nut is a rubber plug that needs to be pushed out. You can sometimes push that out from the access panel. Spray the cables and wire with oil and it will move easier. Now pull the kill wires back out a little ways of the access panel a couple inches try not to pull them completely out. Now you can pull the plastic cage out a couple inches then push it back in. the switch should stay out and not go back in with the cage. Now cut the wires off of the old switch and use those to fish the wires for the new switch. You should not need any heat to do this. Make sure the throttle lock is loose or the cage wont move. Those are generally a PIA to replace. Make sure you remove the wirez from the motor.
 
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