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Suddenly, It's really hard to shift into Reverse on my 1998 Yamaha C115 2 Cycle

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  • #31
    you need to look harder at the parts break down.

    the clutch dog is on the prop shaft not the drive shaft

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    • #32
      Sorry...mistype.... I was running a bit late and just wanted to post my thought before I went to work. Yes it is the prop shaft - not the driveshaft -that holds the clutch dog. I’m still learning, so any other advice or suggestions are greatly appreciated ..... this forum has been a tremendous resource over the years for me. This is the first time I’ve tackled a fix this deep into my lower unit. Thank you for reading my post and catching that!

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      • #33
        so you realize that with the clutch dog pinned to the prop shaft, you cannot pull the prop shaft without unpinning that,
        and only way I know to remover that pin is after the whole propshaft , gear, bearing, and carrier is out of the lower unit housing

        did you open the link I posted earlier and look at the parts breakdown?
        Last edited by 99yam40; 1 week ago.

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        • #34
          I believe I understand the illustration. Correct me if I'm wrong, but isn't the Shift Shaft located furthest inside the prop shaft boot and the Clutch Dog in between that and the prop? I've seen a few You Tube videos that support the fact that by removing the shift shaft rod after the motor is placed in neutral, the Prop shaft easily comes out.. Maybe thats just on certain Yamaha outboards. Once the Prop Shaft is removed, clutch dog components, gear and bearing removals are done. How could you pull the Clutch Dog pin if the prop shaft assembly is still encased in the LU boot. I could be completely way off on my assumptions.... I'm just trying to make sense of it and pull the dam thing out with minimal damage!
          Attached Files

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          • #35
            with the clutch dog pinned to the prop shaft, the prop shaft cannot come thru the gear, bearing, and carrier.
            so if you have already pulled the carrier, then you just need to pull the prop shaft, gear, and bearing if that did not stay in the carrier when you pulled that.

            rig up a slide hammer to thread onto the prop shaft and pop them out
            usually it is the carrier that is the hold up

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            • #36
              Thanks for your patience with me! I finally understand what you’re speaking about. I was successful and re-moving the bearing but I am unable to grab the gear to pull it out to gain access to the clutch dog pin. It’s still seems tied into the driveshaft pinion that cannot be pulled out unless you get to the pinion nut. I’m so close - yet still stuck. How would I go about doing that?

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              • #37
                drive shaft and pinion are on the inside of that gear so they are not holding that propshaft from coming out.
                prop shaft with the clutchdog and gear should come out.
                as I said rig up something to attach a slide hammer to the threaded prop shaft

                now if the prop shaft is stuck to the bearing in the nose of the housing or the reverse gear on the other side of the pinion that could cause another set of problems
                Last edited by 99yam40; 1 week ago.

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                • #38
                  Gotcha! I’ll rig up a puller next directly on the shaft. I originally misunderstood your direction and tried to take off the bearing first then the pinion, but now I completely get it! I think the shift slider is Jammed at the nose and has been the issue in preventing that assembly from pulling out. I’m going to push it a bit at the shift shaft opening as the Service Manual indicates with a long stem screwdriver to carefully coax it out. Thanks for the guidance

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                  • #39
                    I fabricated something to use the slide hammer with using the threads on the prop shaft like you suggested. It's still real stubborn! I sprayed some release agent around the prop shaft and gear in the boot to soak it a bit in hopes it will break free. When I look in the boot from the prop shaft , I see the thrust washer and the reverse gear behind it. The thrust washer seems to be fused to the inside boot. The Gear is free of that washer but still being held in. Do you recommend some heat on it?

                    I'm beginning to think this was a pre-existing issue when I bought the motor in 2015. The first thing I did before I ran it was drop the LU oil. It was milky so I decided to change out the lower prop seals , water pump and upper driveshaft seals. That whole upper seal area under the water pump was rusty. I betcha a little water made it's way inside the boot and created some problems for me. I'll know more as soon as I finally pull it all apart.

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