Attachments Throttle and Shift Linkage...Throttle and Shift Linkage 90-892248R01 JUNE 2005 Page 7A-13 Throttle/Shift Linkage Components (Remote Models) Ref. No. Qty. Description Torque

Throttle and Shift Linkage

90-892248R01 JUNE 2005 Page 7A-1

7A

AttachmentsSection 7A - Throttle and Shift Linkage

Table of Contents

Shift Components (Non‑Bigfoot)......................7A-4Shift Components (Bigfoot)..............................7A-8Throttle/Shift Linkage Components (RemoteModels)..........................................................7A-12Throttle Only Operation..................................7A-14Tiller Handle Models......................................7A-14

Throttle/Shift Removal............................7A-14

Throttle Only Disassembly......................7A-16Throttle Only Assembly...........................7A-18Throttle/Shift Installation.........................7A-21

Remote Models..............................................7A-23Throttle/Shift Removal............................7A-23Throttle/Shift Installation.........................7A-26


Page 7A-2 90-892248R01 JUNE 2005

Lubricant, Sealant, AdhesivesTube Ref No. Description Where Used Part No.

95 2-4-C Marine Lubricant with Teflon

Shift componentsThrottle only gear

Shift detentShift arm

92-802859A1


Notes:

90-892248R01 JUNE 2005 Page 7A-3


Page 7A-4 90-892248R01 JUNE 2005

Shift Components (Non‑Bigfoot)

1 2

3

4

5

6

7

8

9

10

11

12

13

14 15

16

17

18

19

20

2122

23

24

25

26

27

2928

30

31 333532 34

3638

37 39

40

41 42 13

43

44

14 15

16

19

1718

95

95

95

95

8873


90-892248R01 JUNE 2005 Page 7A-5

Shift Components (Non-Bigfoot)

Ref. No. Qty. Description

Torque

Nm lb. in. lb. ft.

1 1 Cam ‑ clutch

2 1 Roll pin

3 1 Shift shaft

4 1 Bushing ‑ Lower shift shaft

5 1 O‑ring

6 1 O‑ring

7 1 Coupler ‑ Shift shaft

8 1 Nut Drive tight

9 1 Reverse lock link actuator

10 1 Screw Drive tight

11 1 Shift shaft ‑ Upper

12 1 Shift detent (Handle)


14 1 Washer

15 1 Bracket

16 2 Bolt 6 53

17 1 Clamp ‑ Shift detent

18 1 Spring ‑ Shift detent

19 1 Bolt 6 53

20 1 Shaft (Handle)

21 1 Pin (Handle)

22 1 Spring (Handle)

23 1 Gear plate (Handle)

24 3 Bolt (Handle) 6 53


26 1 Driven gear (Handle)

27 1 Seal (Handle)

28 1 Knob (Handle)


30 1 Throttle rod (Handle)


32 1 Bushing (Handle)

33 1 Throttle lever (Handle)

34 1 Washer (Handle) (Handle)

35 1 Throttle pulley (Handle)

36 1 Drive gear (Handle)


38 1 Washer (Handle)

39 1 Nut (Handle)

40 1 Shift lever shaft (Remote Control)


Page 7A-6 90-892248R01 JUNE 2005


Torque

Nm lb. in. lb. ft.

41 1 Seal (Remote Control)

42 1 Shift lever (Remote Control)

43 1 Snap retainer (Remote Control)

44 1 Shift detent (Remote Control)

45 1 Stopper


Tube Ref No. Description Where Used Part No.

95 2-4-C Marine Lubricant withTeflon Shift components 92-802859A1


90-892248R01 JUNE 2005 Page 7A-7

Shift Components (Non-Bigfoot)

1 2

3

4

5

6

7

8

9

10

11

12

13

14 15

16

17

18

19

20

2122

23

24

25

26

27

2928

30

31 333532 34

3638

37 39

40

41 42 13

43

44

14 15

16

19

1718

95

95

95

95

8873


Page 7A-8 90-892248R01 JUNE 2005

Shift Components (Bigfoot)

1

2

3

4

5

67

8

910

11

12

1314

15

16

1718

19

2021

2223

2425

26

27

28

29

30

31 3233

34

3536 37 38 39

40 41 42 43

26

2425

19

2017

18

44

45 46

47

48

8876

95

95

95

95


90-892248R01 JUNE 2005 Page 7A-9



Torque

Nm lb. in. lb. ft.

1 1 Cam ‑ clutch (Component of complete gear housing)

2 2 Pin (Component of complete gear housing)

3 1 Cam rod (Component of complete gear housing)

4 1 Bushing (Component of complete gear housing)

5 2 O‑ring (Component of complete gear housing)

6 1 O‑ring (Component of complete gear housing)

7 1 Clamp (Component of complete gear housing)

8 1 Screw (Component of complete gear housing)

9 1 Stopper


11 1 Coupler ‑ Shift shaft

12 1 Nut Drive tight

13 1 Reverse lock actuator


15 1 Shift shaft ‑ Upper

16 1 Shift detent (Handle)


18 1 Washer

19 1 Bracket

20 2 Bolt 6 53

21 1 Shaft (Handle)

22 1 Pin (Handle)

23 1 Spring (Handle)

24 1 Clamp ‑ Shift detent

25 1 Spring ‑ Shift detent

26 1 Bolt 6 53




30 1 Driven gear (Handle)

31 1 Seal (Handle)

32 1 Knob (Handle)


34 1 Throttle rod (Handle)



37 1 Throttle lever (Handle)


39 1 Throttle pulley (Handle)

40 1 Drive gear (Handle)


Page 7A-10 90-892248R01 JUNE 2005


Torque

Nm lb. in. lb. ft.



43 1 Nut (Handle)

44 1 Shaft ‑ Shift (Remote control)

45 1 Seal (Remote control)

46 1 Shift lever (Remote control)

47 1 Snap retainer (Remote control)

48 1 Shift detent (Remote control)


95 2-4-C Marine Lubricant withTeflon Shift components 92-802859A1


90-892248R01 JUNE 2005 Page 7A-11


1

2

3

4

5

67

8

910

11

12

1314

15

16

1718

19

2021

2223

2425

26

27

28

29

30

31 3233

34

3536 37 38 39

40 41 42 43

26

2425

19

2017

18

44

45 46

47

48

8876

95

95

95

95


Page 7A-12 90-892248R01 JUNE 2005

Throttle/Shift Linkage Components (Remote Models)

2658

1

2

3

45

6

78

9

10

111213

14

15

16

17

11

19

1312

18

20

21

2223

24

25

2322

24 25


90-892248R01 JUNE 2005 Page 7A-13

Throttle/Shift Linkage Components (Remote Models)


Torque

Nm lb. in. lb. ft.

1 1 Bracket

2 2 Bolt

3 2 Nut 6 53

4 1 Shoulder bolt

5 1 Seal

6 1 Bushing

7 1 Bracket ‑ throttle cable

8 1 Bolt 6 53

9 1 Throttle lever

10 1 Spacer

11 1 Cable joint

12 2 Washer

13 2 Cotter pin

14 1 Bolt 6 53

15 1 Washer

16 1 Throttle rod

17 1 Shift arm

18 1 Bolt 6 53

19 1 Washer

20 1 Wave washer

21 1 Shift lever rod

22 2 Cable joint

23 2 Nut

24 2 Washer

25 2 Cotter pin


Page 7A-14 90-892248R01 JUNE 2005

Throttle Only Operation1. Rotate throttle handle to neutral.2. Depress the throttle only button while rotating throttle handle to full forward. Release

throttle only button.NOTE: Engine throttle linkage should increase throttle opening. Gearcase should remainin neutral.3. Rotate throttle handle grip back to neutral. The handle grip should stop in the neutral

detent position.4. Depress the throttle only button while rotating throttle handle grip to full reverse.

Release throttle only button.NOTE: Engine throttle linkage should increase throttle opening. Gearcase should remainin neutral.5. Rotate throttle handle grip back to neutral. The handle should stop in the neutral detent

position.

Tiller Handle ModelsThrottle/Shift Removal

1. Remove throttle cables. Refer to Section 7B ‑ Throttle Cable Removal.2. Remove cable retaining clip and screw. Remove neutral interlock cable from the neutral

interlock lever.

3446

ab c

a - Neutral interlock cableb - Neutral interlock lever

c - Cable retaining clip and screw

3. Remove choke link from choke knob.4. Remove grommet with choke knob and throttle cables.


90-892248R01 JUNE 2005 Page 7A-15

5. Remove throttle link from throttle only lever.

3450

a

b

c

d

e

a - Choke linkb - Choke knobc - Grommet

d - Throttle linke - Throttle only lever

6. Remove carburetor air box and electrical plate.

3453

a

b

a - Carburetor air box b - Electrical plate

7. Remove 2 mounting bolts on throttle only control platform.8. Remove bolt securing neutral interlock cable.9. Remove 2 bolts securing shift detent.10. Remove bolt securing the shift detent spring and clamp.

3437

a

a

b

ccd

a - Throttle only control platform boltsb - Neutral interlock cable bolt

c - Shift detent boltd - Shift detent spring and clamp bolt


Page 7A-16 90-892248R01 JUNE 2005

11. Remove shift shaft from shift detent, using a screwdriver to pry apart.

3563

a b

a - Shift detent b - Shift shaft

12. Remove throttle only assembly.

Throttle Only Disassembly1. Remove screw securing shift detent to the shaft. Slide shift shaft lever off the shaft.2. Remove 3 bolts from gear plate halves. Separate gear plates.

3182

b

ac

c

a - Screwb - Shift detent

c - Gear plate bolt

3. Remove neutral interlock cable from shift detent lever by removing small O‑ring. PlaceO‑ring back on shift detent lever to prevent loss.

c b

3452a

a - Neutral interlock cableb - Shift detent lever

c - O‑ring

4. Depress throttle only button and remove pin.


90-892248R01 JUNE 2005 Page 7A-17

5. Remove throttle only button from the shift shaft. Remove spring from inside of the shaft.

a

c

3183

b

a - Pinb - Shift shaft

c - Throttle only button

6. Remove nut from drive gear assembly bolt.

3185

b

a

a - Nut b - Drive gear

7. Remove gear components from outer gear plate.

3187

abcdef

g

a - Boltb - Washerc - Bushingd - Throttle lever

e - Washerf - Throttle pulleyg - Drive gear

8. Inspect all components for cracks and wear. Replace as required.


Page 7A-18 90-892248R01 JUNE 2005

Throttle Only Assembly1. Install gears aligned in neutral position on outer gear plate. Lubricate gears with 2‑4‑C

with Teflon.

a

b

c

d95

9239

a - Outer gear plateb - Drive gear

c - Driven geard - Gear teeth aligned in neutral

position


95 2-4-C Marine Lubricant withTeflon Throttle only gear 92-802859A1

2. Install throttle pulley on drive gear.

3442

ab

a - Throttle pulley b - Drive gear


90-892248R01 JUNE 2005 Page 7A-19

3. Install bolt through throttle lever components and drive gear/gear plate. Install nut.Tighten to specified torque.

3190

abc

d

e

a - Throttle only boltb - Washerc - Bushing

d - Throttle levere - Washer

Description Nm lb. in. lb. ft.

Throttle only bolt 6 53

4. Install spring into shift lever shaft. Assemble throttle only button through outer gearplate and driven gear. Slide shift shaft over the throttle only button shaft. The flat sectionof the shaft must be positioned as shown.

3441

a b c d e

a - Throttle only buttonb - Driven gearc - Spring

d - Shift shafte - Flat section


Page 7A-20 90-892248R01 JUNE 2005

5. Compress shaft and throttle only button and align hole and slot. Install pin through slotand hole.

a

c

3183

b

a - Pinb - Shaft

c - Throttle only button

6. Install neutral interlock cable on shift detent lever. Secure cable end with O‑ring.

c b

3452a

a - Neutral interlock cableb - Shift detent lever

c - O‑ring

7. Attach inner gear plate to outer gear plate. Install 3 bolts. Tighten to specified torque.8. Install shift detent to shaft. Secure with screw and washer. Drive tight.

3182

b

ac

c

a - Screwb - Shift detent

c - Gear plate bolt


Gear plate bolts 6 53


90-892248R01 JUNE 2005 Page 7A-21

Throttle/Shift Installation1. Ensure gearcase is in neutral.2. Install throttle only assembly in bottom cowl.3. Install shift shaft into shift detent. Lubricate shift shaft lever detent notches with 2‑4‑C

with Teflon.

ab 95

9240

a - Shift shaft b - Shift detent


95 2-4-C Marine Lubricant withTeflon Shift detent 92-802859A1

4. Install 2 mounting bolts on throttle only control platform. Tighten bolts to specifiedtorque.

5. Install plate securing shift rod lever with 2 mounting bolts. Tighten bolts to specifiedtorque.

6. Align pointer on the throttle only pulley with the pointer on the gear plate.7. Install spring and clamp on the shift detent with mounting bolt. Tighten bolt to specified

torque.8. Attach neutral interlock cable with bolt. Tighten bolt to specified torque.

11520

a

a

b

ccd

f

e

a - Throttle only control platform boltsb - Neutral interlock cable boltc - Shift detent bolt

d - Shift detent spring and clamp bolte - Pointer on gear platef - Pointer on throttle only pulley


Throttle only control platform bolt 6 53

Shift detent bolt 6 53


Page 7A-22 90-892248R01 JUNE 2005


Shift detent spring and plate bolt 6 53

Neutral interlock cable bolt 6 53

9. Install neutral interlock cable to neutral interlock lever. Attach cable retaining clip withscrew.

3446

ab c

a - Neutral interlock cableb - Neutral interlock lever

c - Cable retaining clip and screw

10. Check operation of shift linkage. Refer to Section 5A ‑ Shift Operation.11. Attach electrical plate with 3 bolts. Tighten to specified torque.12. Attach carburetor air box and gaskets with 2 bolts. Tighten to specified torque.

3453

a

b

a - Carburetor air box b - Electrical plate


Electrical plate mounting bolts 6 53

Carburetor air box mounting bolts 6 53

13. Install grommet with choke knob and throttle cables.


90-892248R01 JUNE 2005 Page 7A-23

14. Install choke link and throttle link.

3450

a

b

c

d

e

a - Choke linkb - Choke knobc - Grommet

d - Throttle linke - Throttle only lever

15. Install throttle cables. Refer to Section 7B ‑ Throttle Cable/Linkage Installation.

Remote ModelsThrottle/Shift RemovalLINKAGE

1. Remove the bolt holding the grommet retainer to the lower cowl. Remove the grommetretainer and grommet.

2. Remove the snap retainers from the throttle and shift actuating levers.3. Remove washers and cable ends.

ab

c

ob01197

a - Grommet retainer boltb - Snap retainer, throttle end

c - Snap retainer, shift end

4. Remove snap retainers from shift link.


Page 7A-24 90-892248R01 JUNE 2005

5. Remove washers and link.

3558

a

ab

a - Snap retainer b - Link

SHIFT ARM1. Remove bolt and shoulder bolt from shift arm.2. Remove components from lower cowl.

a

b

3550

c

a - Shift armb - Shoulder bolt

c - Bolt

SHIFT COMPONENTS1. Remove neutral interlock cable bolt.2. Remove small O‑ring on shift detent lever and remove neutral interlock cable end.NOTE: Place O‑ring in a safe place for installation.

3554

a

b

c

a - Neutral interlock cable endb - Neutral interlock cable attachment

bolt

c - O‑ring


90-892248R01 JUNE 2005 Page 7A-25

3. Remove bolts, shift detent bracket, and shift detent springs.

b

c

3555

a

d

a - Shift dent plate boltb - Shift detent bracket

c - Shift detent spring boltd - Shift detent spring

4. Remove screw securing shift lever shaft to shift detent.

3556

a

b

c

a - Screwb - Shift lever shaft

c - Shift detent

5. Remove snap retainer securing shift lever on shift lever shaft.

3560

ab

c

a - Shift lever shaftb - Snap retainer

c - Shift lever


Page 7A-26 90-892248R01 JUNE 2005

6. Remove shift lever shaft from shift detent by pulling shaft out through opening in lowercowl.

3562

a

b c

da - Shift lever shaft threaded holeb - Shift lever

c - Shift detentd - Lower cowl opening

7. Remove shift shaft from shift detent, using a screwdriver to pry apart.

3563

a b


8. Remove shift shaft lever from lower cowl housing.

Throttle/Shift InstallationSHIFT COMPONENTS

1. Install shift detent into lower cowl.2. Install shift shaft into shift detent. Lubricate detent notches with 2‑4‑C with Teflon.

a b95

9243



90-892248R01 JUNE 2005 Page 7A-27


95 2-4-C Marine Lubricant withTeflon Shift detent 92-802859A1

3. Install shift lever shaft through opening in lower cowl.4. Install shift lever on shaft with arm aligned to threaded hole in shaft.5. Push shift lever shaft into shift shaft lever.

3561

a

b c

da - Shift lever shaft threaded holeb - Shift lever

c - Shift detentd - Lower cowl opening

6. Install snap retainer on groove on shift shaft.

3560

ab

c

a - Shift lever shaftb - Snap retainer

c - Shift lever

7. Install screw through shift detent lever into shift shaft. Drive tight.

3556

a

b

c

a - Screwb - Shift lever shaft

c - Shift detent lever


Page 7A-28 90-892248R01 JUNE 2005

8. Install shift lever plate and shift detent springs. Tighten bolts to specified torque.

b

c

3555

a

d

a - Shift detent bracket boltb - Shift detent bracket

c - Shift detent spring boltd - Shift detent spring and clamp


Shift detent bolt 6 53

Shift detent spring and clamp bolt 6 53

9. Install neutral interlock cable end to shift shaft lever. Secure with bolt.10. Install small O‑ring on shift lever arm.

3554

a

b

c

a - Neutral interlock cable endb - Neutral interlock cable attachment

bolt

c - O‑ring


Neutral interlock cable bolt 6 53

SHIFT ARM1. Install shift arm components through lower cowl.


90-892248R01 JUNE 2005 Page 7A-29

2. Thread bolt into shoulder bolt. Tighten bolt to specified torque.

a

b

c

a

b

c

de

g

3553

f

95

a - Shift armb - Shoulder boltc - Bolt and washerd - Seal

e - Bushingf - Wave washerg - Flat washer


Shift arm bolt 6 53


95 2-4-C Marine Lubricant withTeflon Shift arm 92-802859A1

LINKAGE1. Install link and washers.2. Install snap retainers.

3558

a

ab

a - Snap retainer b - Link

3. Install cable end to the throttle and shift actuating levers.4. Install washers and snap retainers.


Page 7A-30 90-892248R01 JUNE 2005

5. Install grommet in the lower cowl. Attach grommet retainer with bolt. Tighten bolt tospecified torque.

ab

c

ob01197

a - Grommet retainer boltb - Snap retainer, throttle end

c - Snap retainer, shift end


Grommet retainer bolt 6 53

Documents

Attachments Throttle and Shift Linkage...Throttle and Shift Linkage 90-892248R01 JUNE 2005 Page 7A-13 Throttle/Shift Linkage Components (Remote Models) Ref. No. Qty. Description Torque