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Author Topic:   Hard Shifting 90 Four Stroke

ghefty posted 03-16-2004 12:15 PM ET (US)
Shifting (especially into reverse) on my 90-4s is very stiff, my wife can't do it without using two hands. I've had the dealer look at it, they disconnected the cables and confirmed that the problem is in the motor not in the shift cable or binnacle. They checked with Mercury for a service bulletin and were advised to remove the lower unit to clean and lubricate the internal shifting linkage, that freed it up somewhat for a short time. But after a couple of months I'm back to a hard shift. The dealer mentioned that this is a common problem in four strokes. I'd like to hear from other 90-4s owners, how does your engine shift?
Thanks,
George Hefty
'03 M170 90-4s, Pate 27, Aquaworld UT-13
Maximus posted 03-16-2004 08:38 PM ET (US)
My '03 90HP Mercury 4stroke shifts with a clunk. I made the dealer adjust the cable prior to delivering the boat. I think careful yet determined shifting motion has helped smooth things out.
AQUANUT posted 03-17-2004 09:35 AM ET (US)
your not gonna believe this..but...here goes...I rig hondas/yamahas/mercurys for a living...i own a 2004 mercury 115hp efi 4 stroke....it has the same shift platform as the 90 fourstroke....they shift hard if not adjusted perfectly at the platform.it took some time and pain in my arse..to find the correct spot on some moters....which is aggrevating
because they charge 60 bucks an hour for the work I do,,I try hard to be fast and effiecent.

check...re-adjust the shift cable at the motor shift platform
ghefty posted 03-17-2004 01:57 PM ET (US)
Thanks for the advice. I'll discuss the connection points with the service manager. Given the response or lack thereof, this appears to be a somewhat isolated problem, that's a good thing.
On my issue, careful and determined shifting is what I'm striving for, to shift into forward gear takes 5-10 pounds of pressure on the throttle, to return to neutral takes less than that. When shifting into reverse gear I must apply 25-30 pounds of pressure. This makes the careful and determined shifting absolutely necessary. So far, this has not been an issue when operating in close quarters, as I try to maintain safe speeds and distances. Additionally, I'm also concerned with the deterioration of the binnacle and cable since I don't know if they were designed to handle that much stress. I'm dropping the boat off at the dealer this weekend.
Barney posted 03-17-2004 07:50 PM ET (US)
George, Mine doesn't have that problem. I have the Mercury "clunk" but sometimes I'm not so "careful" with shifting.
AQUANUT, With these factory installed outboards are the shifting mechanisms set up at the factory? Or, are they dealer adjusted before the customer receives the boat? Jim
ocuyler posted 03-17-2004 08:17 PM ET (US)
I had the same problem with my 04 115 4s. Merc conceded an "issue" and provided a new lower unit. Haven't tested it yet, but there's something going on with these motors.
My understanding is that a stainless steel prop, due to it's increased weight and momentum exaserbates the problem.
AQUANUT posted 03-17-2004 09:44 PM ET (US)
barney,
boston whalers are sold as a package..with motor and trailer...in regards to the motors..
the larger motors are test run at the factory and inspected for various things...if you look under your cowling..you will often see inspection labels of inspectors...such as Jack Frost
the steering/throttle/shift cables are attached when motor is installed at factory by factory riggers....unfortunately, in most cases..the motors at a factory is not "ran-out" by the rigger that installed it.
due to production..

However...the selling dealership is responsible for conducting a proper PDI.....pre-delivery inspection.
which includes running the engine and checking the throttle and shift adjustments....failure to do this PDI and fill out the pdi inspection form...can cause the dealership some heartache from mercury....
bottomline....a service-manager/certified mercury technican who has their hands on your boat should and usually do make the right call in regards to issues....not someone online who has never had his eyes or ears near your boat....
I am just suggesting a possible course of investigation based on what you have told me....this is the direction i would take.......but nothing surprises me anymore...
good luck
Barney posted 03-17-2004 10:15 PM ET (US)
Thanks AQUANUT, I don't want to imply that anything is wrong with mine. I'm happy. But you confirmed what I suspected. Most do a good job too.
Jim

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Author	Topic: Hard Shifting 90 Four Stroke
ghefty	posted 03-16-2004 12:15 PM ET (US) Shifting (especially into reverse) on my 90-4s is very stiff, my wife can't do it without using two hands. I've had the dealer look at it, they disconnected the cables and confirmed that the problem is in the motor not in the shift cable or binnacle. They checked with Mercury for a service bulletin and were advised to remove the lower unit to clean and lubricate the internal shifting linkage, that freed it up somewhat for a short time. But after a couple of months I'm back to a hard shift. The dealer mentioned that this is a common problem in four strokes. I'd like to hear from other 90-4s owners, how does your engine shift? Thanks, George Hefty '03 M170 90-4s, Pate 27, Aquaworld UT-13
Maximus	posted 03-16-2004 08:38 PM ET (US) My '03 90HP Mercury 4stroke shifts with a clunk. I made the dealer adjust the cable prior to delivering the boat. I think careful yet determined shifting motion has helped smooth things out.
AQUANUT	posted 03-17-2004 09:35 AM ET (US) your not gonna believe this..but...here goes...I rig hondas/yamahas/mercurys for a living...i own a 2004 mercury 115hp efi 4 stroke....it has the same shift platform as the 90 fourstroke....they shift hard if not adjusted perfectly at the platform.it took some time and pain in my arse..to find the correct spot on some moters....which is aggrevating because they charge 60 bucks an hour for the work I do,,I try hard to be fast and effiecent. check...re-adjust the shift cable at the motor shift platform
ghefty	posted 03-17-2004 01:57 PM ET (US) Thanks for the advice. I'll discuss the connection points with the service manager. Given the response or lack thereof, this appears to be a somewhat isolated problem, that's a good thing. On my issue, careful and determined shifting is what I'm striving for, to shift into forward gear takes 5-10 pounds of pressure on the throttle, to return to neutral takes less than that. When shifting into reverse gear I must apply 25-30 pounds of pressure. This makes the careful and determined shifting absolutely necessary. So far, this has not been an issue when operating in close quarters, as I try to maintain safe speeds and distances. Additionally, I'm also concerned with the deterioration of the binnacle and cable since I don't know if they were designed to handle that much stress. I'm dropping the boat off at the dealer this weekend.
Barney	posted 03-17-2004 07:50 PM ET (US) George, Mine doesn't have that problem. I have the Mercury "clunk" but sometimes I'm not so "careful" with shifting. AQUANUT, With these factory installed outboards are the shifting mechanisms set up at the factory? Or, are they dealer adjusted before the customer receives the boat? Jim
ocuyler	posted 03-17-2004 08:17 PM ET (US) I had the same problem with my 04 115 4s. Merc conceded an "issue" and provided a new lower unit. Haven't tested it yet, but there's something going on with these motors. My understanding is that a stainless steel prop, due to it's increased weight and momentum exaserbates the problem.
AQUANUT	posted 03-17-2004 09:44 PM ET (US) barney, boston whalers are sold as a package..with motor and trailer...in regards to the motors.. the larger motors are test run at the factory and inspected for various things...if you look under your cowling..you will often see inspection labels of inspectors...such as Jack Frost the steering/throttle/shift cables are attached when motor is installed at factory by factory riggers....unfortunately, in most cases..the motors at a factory is not "ran-out" by the rigger that installed it. due to production.. However...the selling dealership is responsible for conducting a proper PDI.....pre-delivery inspection. which includes running the engine and checking the throttle and shift adjustments....failure to do this PDI and fill out the pdi inspection form...can cause the dealership some heartache from mercury.... bottomline....a service-manager/certified mercury technican who has their hands on your boat should and usually do make the right call in regards to issues....not someone online who has never had his eyes or ears near your boat.... I am just suggesting a possible course of investigation based on what you have told me....this is the direction i would take.......but nothing surprises me anymore... good luck
Barney	posted 03-17-2004 10:15 PM ET (US) Thanks AQUANUT, I don't want to imply that anything is wrong with mine. I'm happy. But you confirmed what I suspected. Most do a good job too. Jim