25 HP merc tiller handle problems

[XstreamVking]

Any little motor experts on here? My 2001 25hp has a tiller problem, it seems to have slipped? and now the start, fwd and rev marks don't line up. Before I mess sumptin up I thought I would get some ideas on what could be the problem. Thanks for any help.

[njj502]

I got a 2005 at home and I thought there was a cable in there and an adjuster. I've got a service manual at home and the motor.... I'll try to remember to take a look tonight and see what might be up.

PM'd you my phone number, give me a shout after 7pm CST if you want.

Nick

[fastjeff]

Ain't that set up a pain in the *ss! There's a couple of adjustments at the end of those Mickey Mouse cables that should get everything lined back up.

Jeff

[XstreamVking]

Before I started taking it apart Ithought fo sho the cable adj was the problem. It wasn't...I can't tell if it slipped at the cable pulley or if the gears at the throttle /shift had slipped. I found the cables to be good and can't figure out what the heck is wrong. Installing a new cable pulley and some new cables while it is apart. For a little motor they sure are a big PITA. Just throwing new parts at it since I don't know what is wrong..

[fastjeff]

"I feel your pain!" (Bill Clinton)

Doncha love all those plastic parts that snap if you look at them crosseyed!

I suspect the pulley on the tiller slipped somehow. Good luck!

Jeff

[njj502]

Will it still only start in neutral?? I wonder if the rubber just didn't slip on the actual stick.

[rev.ronnie]

Have two of them. Those shiftable tiller handles are the best thing ever for fishing. My dad misses his like crazy now that he has to shift his Honda. I even retro fitted that handle to the helm of the pontoon I have one on. its nice that it swings up and out of the way. I had to make 10' cables...what a pain in the butt though.

I have a brand new handle assy. here from the motor on my 10' tunnel hull if you need me to look at anything in particular. It is off and disassembled.

Remove they spring loaded lever on the flywheel so it will start in any gear, it's way better than ripping your fingers off when you pull it after it kills at idle and you go to restart.

[Tom Foley]

Why they ever changed from the old setup i'll never know !! My 2011 Yamaha still has a seperate shift and throttle !!

[XstreamVking]

Njj502, rev and fast jeff, Thanks for the response! Wish it had just slipped..... Just got some parts to rebuild it. Pulley and cables. After some more looking at it, I think it slipped at the pulley cable to tiller shaft connection and got out of sync at the plastic gears where the throttle and shift happens. Some new parts and some more head scratching may fix it. It would start and go into fwd with working throttle. Rev would engage and not give any throttle. I will update when some parts are replaced and it's re-assembled. Had it since 2001 when new, 1st problem ever so can't say anything bad about the motor.

[XstreamVking]

Took the whole thing apart. (holy crap) Finally found that the alum tiller shaft has a molded on plastic drive pc at the cable/pulley end. And it had stripped. It was a simple fix even for me. Just drilled and tapped thru the plastic pc into the alum handle. Installed a #10 screw in the threaded hole and it was good. Kinda hard to find the problem, but really easy fix. I am now an un-official 25 hp merc tiller expert

[fastjeff]

Great! I'll send you all of my Merc 25 tiller customers!

Jeff

[njj502]

Glad you got it going. I love mine, its an 05 and has less than 75 hours on it. Dads got it now with the jet pump on it for duck hunting and swears its the easiest starting o/b he's ever tugged the rope on

[XstreamVking]

Agree on the quality and toughness of the motor. Mine is a 15'' elec start and has been used from the keys/everglades to N Carolina. Run it on a 13' homemade tunnel skiff. ss merc prop, runs low 30's. My son has ran it since he was 13, he's graduated college and still uses it. Mine has 1000+ hrs on it. Prob never sell it....

[njj502]

We're you having problems shifting it? Mine won't go into reverse now. Acting like its bound up. I did tear a prop up recently, hope I didn't hurt something