Shift Shaft Lever Removal

[STalak]

MC1 (888)

Got her put back together, fired up, fine tuned the motor and the shifting when all of a sudden no shifting in the outdrive.
Pulled the drive back off and the bushing and pin on the lever were sitting in the bottom of the cavity.
I have a new lever on order. My dilemma is I cannot budge the Allen screw. Broke off an impact bit on my 3/8 impact wrench.
Does this thing need to be heated?
Or can I just split the old lever around the screw since I'm replacing it?
Any suggestions are greatly appreciated.

 

[Droid]

Are you talking about the vertical shaft that passes thru the exhaust cavity? If yes, heat would have helped but it's too late now.
Cut the thing in half within the exhaust passage, slide the top up & the bottom down. You'll need shaft #25, lever #29 washer #30 & set screw #31.

 

[kghost]

MC1 (888)

Got her put back together, fired up, fine tuned the motor and the shifting when all of a sudden no shifting in the outdrive.
Pulled the drive back off and the bushing and pin on the lever were sitting in the bottom of the cavity.
I have a new lever on order. My dilemma is I cannot budge the Allen screw. Broke off an impact bit on my 3/8 impact wrench.
Does this thing need to be heated?
Or can I just split the old lever around the screw since I'm replacing it?
Any suggestions are greatly appreciated.

This is very common on assemblies that have not been apart in decades.
I have drilled them out with success and if you try this start with a smaller drill bit to get a starter hole.
As you can see in the attached image, only the first 1/4" or so is threaded so that is all that will need o be drilled out until you are able to get it loose/out. Material is Stainless Steel so Cobalt drill bits would be best to use.