Turd Polishing

[MrGiggles]

The weather has kind of put a hold on things, my shop is not heated. Got the transom wood sealed yesterday, will let it dry for a couple days and recoat. Hoping to paint on Sunday.

Parts arrived for the Zuke, but I cannot get the shift shaft apart for the life of me. Pried, pushed, wiggled, tapped, you name it. Might have to pull the powerhead. Someone has been in there before (bolts missing), maybe they tried and gave up. 

[fishinwrench]

There are 3 different shift shaft configurations on Suzuki's.   Which one does yours have?  

And.....Has it ever been in saltwater?

By looking at the pic you posted I wanna say that yours has the low coupler, shift shaft separates after you drop the gearcase 3".   10mm screw.   It doesn't separate up top. 

I may be wrong though.   

[MrGiggles]

14 minutes ago, fishinwrench said:

There are 3 different shift shaft configurations on Suzuki's.   Which one does yours have?

And.....Has it ever been in saltwater?

It came on a Basscat. Can't imagine it ever made it to the coast, the documentation I have shows it has been in Arkansas since 2000. None of the lower unit bolts were corroded.

This is the diagram, I apologize if it's not legible. I have backed that #3 nut off and unhooked the rod from the #2 lever. The #1 shaft will not slide back to disengage the main shift rod.

I'm going to try and look around the other end of that shift shaft tomorrow, it appears to be exposed. Maybe theres an acorn or something jammed in there that's preventing it from sliding.

[fishinwrench]

Put it in Reverse and drop the gearcase, see if there's not a coupler down low on the shift shaft exposed when you do that.  Should be a 10mm screw......or a roll pin.

[MrGiggles]

20 hours ago, fishinwrench said:

Put it in Reverse and drop the gearcase, see if there's not a coupler down low on the shift shaft exposed when you do that.  Should be a 10mm screw......or a roll pin.

Thanks Wrench. I did not find a coupling down low, but I did find the issue.

Removing the lower carb gave just enough access to the shift rod, they needed to come off anyway. A previous "repair" was the issue, looks to me like the factory dowel broke, and somebody installed a machine screw in its place. It's hard to see in the photo, but just to left of center is the shift rod still assembled with that screw.

The gear case dropped right out once I undid that screw. I pulled the old shift rod and will grab one on ebay, there is just enough room to wiggle them out.

[MrGiggles]

Progress is still slow. I'm about sick of this stupid weather. 

Got the shifter situation fixed up and the impeller changed. I still haven't been able to get it to pump water, on the muffs or in a tub. I may need to modify the barrel that I use for small motors to get the water level higher. Seems to be common with Suzukis, they don't like muffs or tanks. At most, I have gotten a small trickle out of the outlet.

I removed the thermostat and filled the motor with water from the top. It drained out of the lower unit pickup grates and through the pee hole as well, so I know the passages are clear.

[fishinwrench]

Yeah the water level has to be high enough to prime the pump housing.  

Should still pump from muffs though.

[MrGiggles]

Update. Figured it out. I blew out the water passages in the powerhead, but in my haste neglected the passage in the lower unit.

A clog of ants were sucked in and split the new impeller. I put the old one back in, and it seems to be pumping fine. Runs decent too.

I'm going to change all the oil lines and flush out the flow meter and check valves. Hopefully it will work alright, theres a lot more to this oil injection stuff than I thought.

[MrGiggles]

Finally shot some paint yesterday. Got the Suzuki controls swapped over and monitor gauge installed.

Started getting the last few fasteners in the transom, waiting on a skinny armed helper to get the last couple that I can't reach. 

Got the Basscat in the shop now, gonna pull the Zuke off and set it on the stand. Just waiting on a seal for the lower unit and she'll be ready for sea trials.

Sold the Merc on Saturday, had a line of people wanting it, thinking I should've asked for more money.

[fishinwrench]

You're doing a fine job.  I'd hire ya.  

Flat rate though.....not hourly 😅