THROTTLE/SHIFT LINKAGE
CONTROLS
Section 7A - Throttle/Shift Linkage
Table of Contents
Throttle and Shift Linkage (Tiller Handle Shift) . . . . 7A-2
Control Cables
(Tiller Handle Shift) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-4
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . 7A-4
Control Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-4
Removal/Disassembly . . . . . . . . . . . . . . . . . . . . . 7A-4
Reassembly/Installation . . . . . . . . . . . . . . . . . . . . 7A-7
Throttle Cam/Control Lever . . . . . . . . . . . . . . . . . . . 7A-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-10
90-826883R03 NOVEMBER 2002
Throttle Cam/Control Lever . . . . . . . . . . . . . . . . . . . 7A-10
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-12
Neutral Interlock Control Lever . . . . . . . . . . . . . . . . 7A-13
Reassembly/Installation . . . . . . . . . . . . . . . . . . . 7A-13
Horizontal Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . 7A-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-15
7
A
Page 7A-1
THROTTLE/SHIFT LINKAGE

Throttle and Shift Linkage (Tiller Handle Shift)

44
1
46
45

17
29
22 18
95 19

42
43
4
21
41
31 3

40
39 32

7
38 6
35 5
34
33
30 25 37
24 28
12 36 27
13
26
8
15 11
16 9

15
14 10

20
37
23
36

95 2-4-C with Teflon

A=LOCAL ELECTRIC ONLY

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 THROTTLE/SHIFT LINKAGE

Throttle and Shift Linkage (Tiller Handle Shift)

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 SWITCH–interlock
2 2 SCREW (M3.5x0.6x16 hex wsh) 20.0 2.3
3 1 LINK interlock
4 1 LEVER–interlock control
5 1 SCREW (M6x1x25 hex hd cap) 120 13.6
6 1 PLAIN WASHER (62x.255x.03)
7 1 BUSHING
8 1 LEVER–backplate
9 1 LEVER–horizontal shift shaft (PORT)
10 1 SHIFT SHAFT (HORIZONTAL)
11 1 SHIFT LINK ASSEMBLY
12 1 SOCKET
13 1 NUT
14 1 THROTTLE LINK ASSEMBLY
15 2 SOCKET
16 1 NUT
17 1 LINK–spark adjustment S/N
18 2 SOCKET USA–0G437999 & BELOW
19 1 NUT BEL– 9926999 & BELOW
20 1 THROTTLE CAM ASSEMBLY S/#
21 1 LEVER–gear shift USA–0G286099 & BELOW
22 1 PRIMARY LEVER BEL–9881099 & BELOW
23 1 WASHER (.62x.255x.03) (Use w/Ref #20)
20 1 THROTTLE CAM ASSEMBLY S/N
21 1 LEVER–gear shift USA–0G286100 thru 0G437999
22 1 PRIMARY LEVER BEL–9881100 thru 9926999
23 1 WASHER (Use w/Ref #20)
24 1 WASHER
25 1 WAVE WASHER
26 1 THROTTLE CAM S/N
27 1 SPRING USA-0G438000 & UP
28 1 SPARK ARM BEL-9927000 & UP
29 1 TIMING LINK
30 1 SECONDARY GEAR
31 1 PRIMARY GEAR
32 1 BUSHING
33 1 BALL–detent
34 1 SPRING
35 1 SCREW (M6x1x20 hex hd cap) 120 13.6
36 1 SCREW (M6x1x25 hex hd cap) 120 13.6
37 1 BUSHING
38 1 WASHER (.62x.255x.03)
39 1 SCREW (M6x1x30) 120 13.6
40 1 WASHER (.62x.255x.03)
41 1 BUSHING
42 1 CONTROL PLATFORM
43 3 SCREW (M5x1x16 hex washer hd) 120 13.6
44 1 PLATE
45 1 STRAP
46 1 SCREW

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THROTTLE/SHIFT LINKAGE

Control Cables (Tiller Handle Shift)

Removal/Installation
Refer to Section 7B for removal and installation instructions.

Control Platform
Removal/Disassembly
1. Disconnect control cables from anchor bracket and pulley as outlined in Section 7B.
2. Disconnect throttle link rod from ball joint of primary throttle lever.

c
e
a

a 57031

a - Cables
b - Bracket
c - Pulley
d - Link Rod
e - Throttle Lever

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 THROTTLE/SHIFT LINKAGE

3. Disconnect shift link rod from ball joint of gear shift lever.

a
57033
a - Shift Link Rod
b - Gear Shift Lever
c - Shift Lever

4. Remove 3 bolts and control platform.

b

57034
a - Bolt
b - Control Platform

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THROTTLE/SHIFT LINKAGE

5. Remove nuts and flat washers.

b 57040
a - Nuts
b - Flat Washers

6. Disassemble control platform.

f
e

c d

b
e
a
h e
i
j 53174

a - Bolts (2) – Torque to 120 lb. in. (13.6 N·m)

b - Flatwashers (2)
c - Primary Gear
d - Bushing (Long)
e - Mount Bolts – Torque to 120 lb. in. (13.6 N·m)
f - Control Platform
g - Bushing (Short)
h - Detent Spring
i - Detent Ball
j - Secondary Gear

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 THROTTLE/SHIFT LINKAGE

Reassembly/Installation
1. Install short bushing and long bushing on control platform.
2. Install detent spring and detent ball into recess of control platform.
3. Lubricate bushings and area of platform traveled by gears with 2-4-C withTeflon.

c b

95

57038
95 2-4-C with Teflon

a - Short Bushing
b - Long Bushing
c - Platform

4. Install secondary gear over short bushing and detent ball and spring as shown.
5. Secure secondary gear with bolt and flat washer. Torque bolt to 120 lb. in. (13.6 N·m).
6. Lubricate gear teeth with 2-4-C with Teflon.

95

95 2-4-C with Teflon 57039

a - Secondary Gear
b - Bolt and Flat Washer – Torque to 120 lb. in. (13.6 N·m)

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THROTTLE/SHIFT LINKAGE

7. Install primary gear over long bushing as shown.

8. Secure primary gear with bolt and flat washer. Torque bolt to 120 lb. in. (13.6 N·m).
9. Lubricate gear teeth with 2-4-C with Teflon.

95

95 2-4-C with Teflon 57040

a - Primary Gear
b - Bolt and Flat Washer – Torque to 120 lb. in. (13.6 N·m)

10. Secure assembled control platform onto cylinder block using 3 bolts. Torque bolts to
120 lb. in. (13.6 N·m).
a

57034
a - Platform
b - Bolts – Torque to 120 lb. in. (13.6 N·m)

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 THROTTLE/SHIFT LINKAGE

11. Adjust shift link rod to a length of 5-1/2 in. (13.9 cm) as measured between ball joint
centerlines.
12. Connect shift link rod between joints of secondary lever and shift shaft lever.

b
c

a
57033
a - Shift Link Rod – Adjust to length of 5-1/2 in. (13.9 cm)
b - Shift Shaft Lever
c - Secondary Lever

13. Adjust throttle link rod to a length of 5-1/4 in. (13.3 cm) as measured between ball joint
centerlines.
14. Connect throttle link rod between ball joints of primary gear and throttle cam.

e
d

b
c

a - Throttle Link Rod – Adjust to length of 5-1/4 in. (13.3 cm)

b - Primary Gear
c - Throttle Cam
d - Pulley
e - Anchor Bracket
f - Control Cables

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THROTTLE/SHIFT LINKAGE

Throttle Cam/Control Lever

Removal
1. Refer to Section 7B for removal of throttle cables.
2. Remove bolt and flat washer securing cam/lever to powerhead.

a b
57041
a - Bolt
b - Washer
c - Cam/Lever

Reassembly
1. Position spring over hub of throttle cam. Spring ends must straddle tab.

b b

c 57042
a - Hub
b - Spring Ends
c - Tab

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 THROTTLE/SHIFT LINKAGE

2. Lubricate bushing with 2-4-C with Teflon and install bushing and wave washer.

95

95 2-4-C with Teflon 57050

a - Bushing
b - Wave Washer

3. Install control lever onto throttle cam assembly so that tab of control lever is positioned
between ends of spring.

c b
57043

a - Control Lever
b - Tab
c - Ends of Spring

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THROTTLE/SHIFT LINKAGE

Installation
1. Secure throttle cam/control lever assembly onto mounting boss of crankcase cover
with bolt. Torque bolt to 120 lb. in. (13.6 N·m).
2. Connect timing link between ball joints of control lever and trigger assembly.

a
e

c
d
57041

a - Throttle Cam
b - Control Lever
c - Flat Washer
d - Bolt – Torque bolt to 120 lb. in. (13.6 N·m)
e - Timing Link

3. Adjust throttle link rod to a length of 5-1/4 in. (13.3 cm) as measured between ball joint
centerlines.
4. Connect throttle link rod between ball joints of throttle cam and primary throttle lever.

c b

57031
a - Throttle Link Rod – Adjust to a length of 5-1/4 in. (13.3 cm)
b - Throttle Cam
c - Primary Gear

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 THROTTLE/SHIFT LINKAGE

Neutral Interlock Control Lever

Reassembly/Installation
1. Lubricate bushing with 2-4-C with Teflon and install bushing.

95
a

95 2-4-C with Teflon 57045

a - Bushing

2. Secure interlock lever components with bolt onto mounting boss of crankcase cover.

57044
a - Interlock Lever
b - Flat Washer
c - Bolt – Torque to 120 lb. in. (13.6 N·m)
d - Neutral Interlock Wire

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THROTTLE/SHIFT LINKAGE

Horizontal Shift Shaft

Removal
1. Remove nut securing access cover to port side of bottom cowl. Remove cover.

57035
a - Nut
b - Access Cover

2. Lift up and remove lever securing horizontal shift shaft.

56915

a - Lever

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 THROTTLE/SHIFT LINKAGE

3. Pull out and remove horizontal shift shaft.

57046

a - Horizontal Shift Shaft

Installation
1. Install horizontal shift shaft/shift lever assembly into opening in STARBOARD side of
crankcase cover.

57046
a - Horizontal Shift Shaft
b - Shift Lever

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THROTTLE/SHIFT LINKAGE

2. Secure end of shift shaft to yoke of horizontal shift shaft with lever.

57047

a - Lever

3. Reinstall access cover and secure with nut and bolt. Torque nut to 50 lb. in. (5.6 N·m).

57035

a - Access Cover
b - Nut – Torque to 50 lb. in. (5.6 N·m)

4. Refer to Control Platform/Throttle Cam/Control Lever previous and reinstall plat-

form, shift link and throttle cam.

Page 7A-16 90-826883R03 NOVEMBER 2002