Mariner 5hp 2t outboard help!

Minerva · 10 Apr 2024

I have in many respects the perfect OB for my tender. The Mariner 5hp 2 stroke. Its light weight, the remote fuel tank means it doesn’t leak petrol over the boot every Friday and Sunday evenings and has ample ooomph for me.

Many years good service it’s offered ‘til last season.

The issue I have is the gear lever to select F/N/R is stiff and now seized solid. The gear box is fine, the issue is the plastic gear lever itself. This plastic lever passes through a metal moulded in bracket in the casing without a grease point. Last season the swelling of the plastic lever got too much for the casing and its siezed solid.

I had a go at removing it to no avail and I have dropped it off with an outboard service mechanic who’s not had much luck either getting it free / out let alone sourcing a replacement.

It feels incongruous to chuck out an otherwise running great outboard for the sake of a bit of plastic.

Any ideas of how I could fix myself / heath robinson a solution to keep it running for a few more years?

Thanks

Minerva · 12 Apr 2024

No one?

VicS · 12 Apr 2024

Minerva said:
No one?

Tried heating the housing with lots of boiling water ?

Maybe the only way will be to cut off the lever and drill out the plastic shaft and replace with a new one.

I think they are metal and plastic now

harvey38 · 13 Apr 2024

Is it possible to drip vinegar onto the shaft from the other side of the shaft? If used in salt water, there could be dried up salt crud in there and vinegar should start to dissolve it.

fisherman · 13 Apr 2024

My Yam will be broadly the same I think. When it seized I had to take off the power head and dress the lever shaft.

Rappey · 13 Apr 2024

I had this issue with a tohatsu 3.5. Was fixable fairly easily as there is a removable plate to get to the inside of it allowing it to be levered out without destroying it, clean up, put back and now it moves without any effort.
Now i have a 4t suzuki 6 with the same problem. Unfortunately this time round the whole power head needs removing to gain access to attempt repair.
I poured and sprayed all sorts over it but it still won't budge.
What i have learnt is if one's gear lever is starting to feel a little stiff, sort it out before it seizes up solid.

Mark-1 · 13 Apr 2024

Rappey said:
What i have learnt is if one's gear lever is starting to feel a little stiff, sort it out before it seizes up solid.

How do you do that? Silicon spray from the outside? Sounds like an issue I need to keep on top of.

mrangry · 13 Apr 2024

My go to penetrant is acetone and auto transmission fluid mix, worth a go

ProDave · 13 Apr 2024

I did a similar repair to a Honda 5HP. It seemed to be a well known problem with the Honda, the plastic bushes swell and the gear change shaft becomes stiff.

The repair for the Honda is well documented, lift the power head out of the leg then remove the pan to give access to the gear change shaft. remove it, ream out the plastic bushes, re assemble with lots of grease and re assemble.

Expect to be repeating in a few years.......

Rappey · 13 Apr 2024

I'm not so sure it's the plastic causing the problems. It's more that the aluminium oxidises and expands, crushing the plastic and eventually seizes everything up.

popeye the sailorman · 13 Apr 2024

Minerva said:
I have in many respects the perfect OB for my tender. The Mariner 5hp 2 stroke. Its light weight, the remote fuel tank means it doesn’t leak petrol over the boot every Friday and Sunday evenings and has ample ooomph for me.

Many years good service it’s offered ‘til last season.

The issue I have is the gear lever to select F/N/R is stiff and now seized solid. The gear box is fine, the issue is the plastic gear lever itself. This plastic lever passes through a metal moulded in bracket in the casing without a grease point. Last season the swelling of the plastic lever got too much for the casing and its siezed solid.

I had a go at removing it to no avail and I have dropped it off with an outboard service mechanic who’s not had much luck either getting it free / out let alone sourcing a replacement.

It feels incongruous to chuck out an otherwise running great outboard for the sake of a bit of plastic.

Any ideas of how I could fix myself / heath robinson a solution to keep it running for a few more years?

Thanks

Hi I have experienced the same problem.
I found plenty of patience and liberal amounts of plus gas eventually paid dividends.
Careful manipulation of the lever Backwards and forwards to avoid it shearing off.
Taking the powerhead off will be necessary to get good access. These are great engines worth hanging onto.

Refueler · 14 Apr 2024

As you say - great engine .. worth sorting out.

It always amazes me how manufacturers can combine materials that later have trouble ... such a simple matter to avoid !

I would assume that hot water ... vinegar .... Plus Gas etc has all been tried ?? It may come down to Brute Force to remove - then need to replace / repair.

fisherman · 14 Apr 2024

I think it's a plastic shaft in ally, so good chance of parting it off. No amount of unguents helped with mine. You may need a gasket for the power head if removed, I didn't bother. Only thing is, although I have done it many times, I could not get the water pipe back in the pump last time, had to drill a hole in the leg and put a bung in it.

Bluefin21 · 22 Apr 2024

Powerhead removal is really the only answer

Mariner 5hp 2t outboard help!

Minerva

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Minerva

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VicS

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harvey38

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fisherman

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Rappey

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Mark-1

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mrangry

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ProDave

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Rappey

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popeye the sailorman

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Refueler

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fisherman

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Bluefin21

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