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Old 06-04-2018, 14:16   #1
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Yamaha 9.9 does not shift into gear after winter storage. Any ideas?

Hi,

we've got an issue with one engine not shifting into gear after winter storage.

The gear lever on the side of the engine seems stuck despite having removed the cables and trying to move it manually.

All was ok before storage.
Prop can be turned freely by hand. Feels pistons are not moved by doing so.
Fogged cylinders before storage.

Its a fairly new Yamaha 9.9 High Thrust engine.

Anything we can try before taking the engine apart?

Thanks Fran
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Old 06-04-2018, 15:00   #2
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Re: Yamaha 9.9 does not shift into gear after winter storage. Any ideas?

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Originally Posted by Franziska View Post
Hi,

we've got an issue with one engine not shifting into gear after winter storage.

The gear lever on the side of the engine seems stuck despite having removed the cables and trying to move it manually.

All was ok before storage.
Prop can be turned freely by hand. Feels pistons are not moved by doing so.
Fogged cylinders before storage.

Its a fairly new Yamaha 9.9 High Thrust engine.

Anything we can try before taking the engine apart?

Thanks Fran
Had the same engine and the same problem.

First, disconnect the shift rod where it is visible in a gap just above the lower unit. You may have to remove the lower unit, which a good time to replace the impeller. This will allow you to determine where it is stuck (in the lower unit or at the swivel/rocker up top).

Most likely it is corrosion in the swivel/rocker under the front of the engine, and it is a bastard child to get to. Try lots of PB Blaster. Be gentle.
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Old 06-04-2018, 15:25   #3
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Re: Yamaha 9.9 does not shift into gear after winter storage. Any ideas?

Spinning the prop is the first thing to do - so you have checked that the gears are free to engage.

If you haven't changed your impeller recently there may be a problem in the gearbox, then you probably should undo the gearshift linkage and see if that frees it up. The linkage is held together with a long nut. You have to undo about 4 bolts too - there may be a bolt hidden (I can't remember - the 25hp has one under a rubber grommet).

You should remove the leg every two years at a minimum - having a st uck leg ruins an engine as you are one impeller from cooking it so take this opportunity to check the impeller anyway.

If you removed the leg (and the gearbox linkage works fine) then the problem is probably in the linkage up top. It could be that corrosion has done its thing there. Be careful as many of these parts are cast alloy and rather brittle - work gently rather than roughly.

On some motors there are little plastic links that can fall off the gearshift, check that they are not fouling the flywheel or insides somehow.

Be careful and gentle. If it is siezed in the gearbox that is bad but you can get another gearbox. Get the leg off and give the shaft a nice lick of grease - it sounds as though the motor needs it.
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Old 06-04-2018, 16:48   #4
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Re: Yamaha 9.9 does not shift into gear after winter storage. Any ideas?

Like others have said, just go ahead and replace the impeller and in the process you will inevitably (in the process) correct the problem.....

It's probably in the shift linkage or associated area.
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Old 07-04-2018, 01:43   #5
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Re: Yamaha 9.9 does not shift into gear after winter storage. Any ideas?

Happened to our 9.9, would not go ahead after astern. Bolt had dropped and jammed shift lever.
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Old 07-04-2018, 11:11   #6
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Re: Yamaha 9.9 does not shift into gear after winter storage. Any ideas?

I have a 15 yamaha & it did the same thing, if you look at where the shift rod goes through the cowling down to the foot it's a tight fit,I sprayed PB blaster there & wiggled the shifter & it came loose, be gentle so you don't break the shifter... but as others are saying it's not a bad time to do impeller as well..I didn't want to take it apart yet so lots of PB & patience and wiggle wiggle and it should come loose. Good luck!
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Old 07-04-2018, 11:18   #7
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Re: Yamaha 9.9 does not shift into gear after winter storage. Any ideas?

Removing the link from the lower unit also allows you to tug it in both directions, which helps.
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Old 07-04-2018, 14:43   #8
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Re: Yamaha 9.9 does not shift into gear after winter storage. Any ideas?

I'd say its the morse cable, (cable like bonnet release cable on a car but bigger), disconnect place in vise poor penetrant in and work it, it'll be obvious if this is the cause. If so, Measure it with a view to replace, if its free enough it would be OK to use for a while.
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Old 08-04-2018, 04:53   #9
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Re: Yamaha 9.9 does not shift into gear after winter storage. Any ideas?

Unnecessary posting.
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Old 08-04-2018, 04:54   #10
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Re: Yamaha 9.9 does not shift into gear after winter storage. Any ideas?

Unnecessary posting.
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Old 08-04-2018, 05:06   #11
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Re: Yamaha 9.9 does not shift into gear after winter storage. Any ideas?

I had to hold the shift rod with a pair of needle nose pliers (through the small hole in the lower unit housing) while I loosened the screw on the connecting rod linkage. It's even more "fun" reassembling all this!

Your Yamaha may have a different setup for the shift linkage than my 2011 5 hp Mercury 4 stroke but most outboards have something similar

Looks like your engine is quite different than mine. Here's a how to video but he doesn't disassemble. You may be able to find a better video for your engine on youtube though

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Old 08-04-2018, 05:40   #12
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Re: Yamaha 9.9 does not shift into gear after winter storage. Any ideas?

Disassembly was fine.

Managed to turn the link rod nut the last 2 turns by hand...
Impeller is like new, no cracks or dirt...
Gear shift rod in upper leg can be moved a bit horizontally. WD40 runs through along rod. So I suppose shift rod is not stuck.
As gearbox/lower leg and cables are not attached and lever is still stuck I suppose it's in the link between lever and rod at upper end.
Will try to disassemble that as next.

Thanks for all the ideas and help so far.
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Old 08-04-2018, 06:36   #13
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Re: Yamaha 9.9 does not shift into gear after winter storage. Any ideas?

You may also want to search online for a free shop manual for your outboard.

There's a 225 page plus manual for my motor free online.......maybe for yours also

Maybe something like this. Not sure what year your engine is:

http://www.google.com/url?sa=t&rct=j...VOz0C9MD-h-xZX
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Old 08-04-2018, 07:22   #14
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Re: Yamaha 9.9 does not shift into gear after winter storage. Any ideas?

Awesome. I'll look at it. My engines are 2014 models.
9.9 High Thrust.
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Old 08-04-2018, 07:54   #15
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Re: Yamaha 9.9 does not shift into gear after winter storage. Any ideas?

Lower leg is reattached.
Used plenty of grease and Tefgel in the process.

Pistons can be moved manually without issues.

Well, I can see the lever assembly in the manual, but I really fear that I need to take the full power head off to get to it. What a pain...!
Anyone with a better idea to try first?
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