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
Throttle and Shift Linkage
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
Throttle and Shift Linkage
Notes:
90-892248R01 JUNE 2005 Page 7A-3
Throttle and Shift Linkage
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
Throttle and Shift Linkage
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)
13 1 Screw Drive tight
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
25 1 Gear plate (Handle)
26 1 Driven gear (Handle)
27 1 Seal (Handle)
28 1 Knob (Handle)
29 2 Bolt (Handle) 6 53
30 1 Throttle rod (Handle)
31 1 Bolt (Handle) 6 53
32 1 Bushing (Handle)
33 1 Throttle lever (Handle)
34 1 Washer (Handle) (Handle)
35 1 Throttle pulley (Handle)
36 1 Drive gear (Handle)
37 1 Bushing (Handle)
38 1 Washer (Handle)
39 1 Nut (Handle)
40 1 Shift lever shaft (Remote Control)
Throttle and Shift Linkage
Page 7A-6 90-892248R01 JUNE 2005
Ref. No. Qty. Description
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
46 1 Screw Drive tight
Tube Ref No. Description Where Used Part No.
95 2-4-C Marine Lubricant withTeflon Shift components 92-802859A1
Throttle and Shift Linkage
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
Throttle and Shift Linkage
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
Throttle and Shift Linkage
90-892248R01 JUNE 2005 Page 7A-9
Shift Components (Bigfoot)
Ref. No. Qty. Description
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
10 1 Screw Drive tight
11 1 Coupler ‑ Shift shaft
12 1 Nut Drive tight
13 1 Reverse lock actuator
14 1 Screw Drive tight
15 1 Shift shaft ‑ Upper
16 1 Shift detent (Handle)
17 1 Screw Drive tight
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
27 1 Gear plate (Handle)
28 3 Bolt (Handle) 6 53
29 1 Gear plate (Handle)
30 1 Driven gear (Handle)
31 1 Seal (Handle)
32 1 Knob (Handle)
33 2 Bolt (Handle) 6 53
34 1 Throttle rod (Handle)
35 1 Bolt (Handle) 6 53
36 1 Bushing (Handle)
37 1 Throttle lever (Handle)
38 1 Washer (Handle)
39 1 Throttle pulley (Handle)
40 1 Drive gear (Handle)
Throttle and Shift Linkage
Page 7A-10 90-892248R01 JUNE 2005
Ref. No. Qty. Description
Torque
Nm lb. in. lb. ft.
41 1 Bushing (Handle)
42 1 Washer (Handle)
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)
Tube Ref No. Description Where Used Part No.
95 2-4-C Marine Lubricant withTeflon Shift components 92-802859A1
Throttle and Shift Linkage
90-892248R01 JUNE 2005 Page 7A-11
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
Throttle and Shift Linkage
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
Throttle and Shift Linkage
90-892248R01 JUNE 2005 Page 7A-13
Throttle/Shift Linkage Components (Remote Models)
Ref. No. Qty. Description
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
Throttle and Shift Linkage
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.
Throttle and Shift Linkage
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
Throttle and Shift Linkage
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.
Throttle and Shift Linkage
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.
Throttle and Shift Linkage
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
Tube Ref No. Description Where Used Part No.
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
Throttle and Shift Linkage
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
Throttle and Shift Linkage
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
Description Nm lb. in. lb. ft.
Gear plate bolts 6 53
Throttle and Shift Linkage
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
Tube Ref No. Description Where Used Part No.
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
Description Nm lb. in. lb. ft.
Throttle only control platform bolt 6 53
Shift detent bolt 6 53
Throttle and Shift Linkage
Page 7A-22 90-892248R01 JUNE 2005
Description Nm lb. in. lb. ft.
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
Description Nm lb. in. lb. ft.
Electrical plate mounting bolts 6 53
Carburetor air box mounting bolts 6 53
13. Install grommet with choke knob and throttle cables.
Throttle and Shift Linkage
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.
Throttle and Shift Linkage
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
Throttle and Shift Linkage
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
Throttle and Shift Linkage
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
a - Shift detent b - Shift shaft
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
a - Shift detent b - Shift shaft
Throttle and Shift Linkage
90-892248R01 JUNE 2005 Page 7A-27
Tube Ref No. Description Where Used Part No.
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
Throttle and Shift Linkage
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
Description Nm lb. in. lb. ft.
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
Description Nm lb. in. lb. ft.
Neutral interlock cable bolt 6 53
SHIFT ARM1. Install shift arm components through lower cowl.
Throttle and Shift Linkage
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
Description Nm lb. in. lb. ft.
Shift arm bolt 6 53
Tube Ref No. Description Where Used Part No.
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.
Throttle and Shift Linkage
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
Description Nm lb. in. lb. ft.
Grommet retainer bolt 6 53