Alpha 1 Sift Cable Excersizer-No more stalling
 

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See shift_ex.txt and the accociated JPGs.

Alpha 1 Shift cable Excersizer

A problem with Alpha 1 and II outdrive lower units is; with infrequent
use, the movement of the shift cable and transfer link in the lower unit
becomes stiff. This causes the shift interrupter to stall the engine
when shifting from neutral to forward or reverse, or when shifting from
either gear to neutral.
I disassembled the shift quadrant on the engine and could only manually
move the shift cable with difficulty. There was now way I could loosen
the action by manual operation.
Repair requires removal of the outdrive leg to re-lube the transfer link
bushings. If you have a couple buds or a fixture to help manhandle the
heavy, unwieldy leg, the job is fairly easy. Without these requisites,
it's a real PIA.
Having encountered the shift/stall condition( for the 3rd time) in my
Alpha 1 yet again after sitting all winter, I decided to circumvent the
disassembly of the lower unit.
I built a Shift Cable Excersizer using a used Bosch wiper motor. It
mounts to the 2 pins in the shift quadrant. This unit shifts the lower
unit back and forth through forward/neutral/reverse about once a second.
In so doing, it excersizes the whole shift system and frees-up the stiff
action. After a treatment with the Excersizer, I can now easily shift
the cable by hand.
Because the load overheats the wiper motor in 6-7 minutes of operation,
I accommodated the duty cycle by running the Excersizer from a battery
charger and switching the charger with a timer.
The unit uses an Intermatic Digital Programmable light timer model
D717C To operate the motor for a 5 minute period each hour.
Since I was unsure if the wiper motor would have sufficient torque to do
the job, I did not pay particular attention to aesthetics; just worked
out the engineering and whacked it together from odds and ends around
the shop.

JR
--------------------------------------------------------------
Home Page: http://www.seanet.com/~jasonrnorth

JR
If you have not replaced the shift bushings, I suggest you do so.
Greasing them wont help much if the seals are shot. Also take a close look
at the shaft for pitting in the seal area and the arm roller for excessive
looseness and nicks or gouges. If the seals are shot you will also have a
lower shift cable that will fail sooner or later, due to water intrusion
between the core and housing.
JIMinFL

"JR North" wrote in message
...
-- Pics in the Dropbox
http://www.metalworking.com/DropBox/
See shift_ex.txt and the accociated JPGs.

Alpha 1 Shift cable Excersizer

A problem with Alpha 1 and II outdrive lower units is; with infrequent
use, the movement of the shift cable and transfer link in the lower unit
becomes stiff. This causes the shift interrupter to stall the engine when
shifting from neutral to forward or reverse, or when shifting from either
gear to neutral.
I disassembled the shift quadrant on the engine and could only manually
move the shift cable with difficulty. There was now way I could loosen the
action by manual operation.
Repair requires removal of the outdrive leg to re-lube the transfer link
bushings. If you have a couple buds or a fixture to help manhandle the
heavy, unwieldy leg, the job is fairly easy. Without these requisites,
it's a real PIA.
Having encountered the shift/stall condition( for the 3rd time) in my
Alpha 1 yet again after sitting all winter, I decided to circumvent the
disassembly of the lower unit.
I built a Shift Cable Excersizer using a used Bosch wiper motor. It mounts
to the 2 pins in the shift quadrant. This unit shifts the lower unit back
and forth through forward/neutral/reverse about once a second. In so
doing, it excersizes the whole shift system and frees-up the stiff action.
After a treatment with the Excersizer, I can now easily shift the cable
by hand.
Because the load overheats the wiper motor in 6-7 minutes of operation, I
accommodated the duty cycle by running the Excersizer from a battery
charger and switching the charger with a timer.
The unit uses an Intermatic Digital Programmable light timer model D717C
To operate the motor for a 5 minute period each hour.
Since I was unsure if the wiper motor would have sufficient torque to do
the job, I did not pay particular attention to aesthetics; just worked out
the engineering and whacked it together from odds and ends around the
shop.

JR
--------------------------------------------------------------
Home Page: http://www.seanet.com/~jasonrnorth

My boat sits all winter and shifts fine day one. I think you have other
problems.

"JR North" wrote in message
...
-- Pics in the Dropbox
http://www.metalworking.com/DropBox/
See shift_ex.txt and the accociated JPGs.

Alpha 1 Shift cable Excersizer

A problem with Alpha 1 and II outdrive lower units is; with infrequent
use, the movement of the shift cable and transfer link in the lower unit
becomes stiff. This causes the shift interrupter to stall the engine when
shifting from neutral to forward or reverse, or when shifting from either
gear to neutral.
I disassembled the shift quadrant on the engine and could only manually
move the shift cable with difficulty. There was now way I could loosen the
action by manual operation.
Repair requires removal of the outdrive leg to re-lube the transfer link
bushings. If you have a couple buds or a fixture to help manhandle the
heavy, unwieldy leg, the job is fairly easy. Without these requisites,
it's a real PIA.
Having encountered the shift/stall condition( for the 3rd time) in my
Alpha 1 yet again after sitting all winter, I decided to circumvent the
disassembly of the lower unit.
I built a Shift Cable Excersizer using a used Bosch wiper motor. It mounts
to the 2 pins in the shift quadrant. This unit shifts the lower unit back
and forth through forward/neutral/reverse about once a second. In so
doing, it excersizes the whole shift system and frees-up the stiff action.
After a treatment with the Excersizer, I can now easily shift the cable
by hand.
Because the load overheats the wiper motor in 6-7 minutes of operation, I
accommodated the duty cycle by running the Excersizer from a battery
charger and switching the charger with a timer.
The unit uses an Intermatic Digital Programmable light timer model D717C
To operate the motor for a 5 minute period each hour.
Since I was unsure if the wiper motor would have sufficient torque to do
the job, I did not pay particular attention to aesthetics; just worked out
the engineering and whacked it together from odds and ends around the
shop.

JR
--------------------------------------------------------------
Home Page: http://www.seanet.com/~jasonrnorth