SHIFTY BUSINESS

Q: Dear Doc, my 2005 Triton 2690 W/A is powered by two 2005 Suzuki 200 hp four-strokes, which have developed a strange problem. At idle and occasionally slightly higher rpm, one engine or the other might refuse to shift out of gear and into neutral. To stop the boat’s movement, the derelict engine must be turned off. After restarting, shifting returns to normal for varying lengths of time (these are analog engines). Technicians have cleaned, lubed, replaced parts at the motor heads, and checked out lower gear boxes. None of these efforts have resulted in any success. What can you suggest?

Ken Mills Richmond, Virginia

A: My contacts at Suzuki were happy to address your question. Their response is below:

It sounds like the control cables are out of adjustment. This is often overlooked.

1. AT THE ENGINE: Remove the cowling. 2. AT THE ENGINE: Remove the starboard pan. You’ll need an 8 mm one-quarter drive socket with extension.

3. AT THE ENGINE: Remove the throttle and shift cables.

These are held on by a small hair-pin clip and should have a stainless-steel washer as well.

4. AT THE HELM: Rock the control-box lever back and forth a few times. 5. AT THE ENGINE: Rock the throttle pin and shifter pin so they are in the center throw of the neutral/idle location. 6. AT THE ENGINE: Adjust the control-cable ends so they will fit on the throttle pin and the shifter pin without moving the pins. The cable ends should slip right on. You can turn the cable ends to move one way or the other because they are threaded. There is a jam nut on the cable. Make sure the cable end is not twisted on the throttle and shifter pins because the jam nut is keeping the cable end out of plum. All of the cable ends need to be in a relaxed state on the pin when in idle and neutral.

7. Reinstall the cables on the throttle pin and shifter pin, then the stainless-steel washer, then the small hair pin.

This is not a hard job. For someone with mechanical skills, this takes about 15 to 20 minutes (for each motor), if the boat is on the trailer. It’s very challenging and not advised if in the water.