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Old 11 November 2008, 16:33   #1
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Clunky gear change

I have a 2001, 200hp Merc. outboard with single lever control. I get a loud clunk when engaging f/ward or reverse. Idle rmp is 800. The bottom end has been recently been rebuilt.
Is this an adjustment problem, the idle rpm too high or, or, or?
Thank you
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Old 12 November 2008, 11:17   #2
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If it's just a clunk, it's probably fairly normal.

You are changing the prop's speed from zero to your 800 idle divided by the gear ratio (somewhere in the 300rpm or so range, I'd guess), so you're going to get some kind of reaction. No clutch to take up the shock.

It's grinding as it goes into gear that I dislike.

This is just my opinion; I'm certainly not a Merc mechanic.


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Old 12 November 2008, 17:45   #3
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That Idle sounds quite high, my old Johnson used to do the same and then I got the idle down to 600 and it did not clunk nearly so badly.
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Old 12 November 2008, 21:18   #4
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Yeh, I was told that most Mercs Cluncked into gear when I was enquiring about mine a few years ago.

If this something that only happened after the rebuilt bottom end then send it back or however rebuilt it. Sorry I can't be of much more help!
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Old 12 November 2008, 23:17   #5
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Thanks for the input. I will try lowering the idle. It is just so embarising in a crowded marina going clunk , clunk, clunk.
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Old 13 November 2008, 11:09   #6
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Yeh, I was told that most Mercs Cluncked into gear when I was enquiring about mine a few years ago.

If this something that only happened after the rebuilt bottom end then send it back or however rebuilt it. Sorry I can't be of much more help!
Yes, mine has always clunked too. I thought all outboards did that - and some outdrives too - except for the newest fly by wire ones. Always seemed poor, primitive engineering to me. But then, what do I know?
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Old 13 November 2008, 13:54   #7
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It's just a dog clutch, it's bound to clunk as it engages. Do it smartly to reduce wear. It'll be worse with a stainless prop than with an ally one.
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Old 13 November 2008, 15:27   #8
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Yes, mine has always clunked too. I thought all outboards did that - and some outdrives too - except for the newest fly by wire ones. Always seemed poor, primitive engineering to me. But then, what do I know?
My Yamaha used to crunch a bit going into reverse if I wasn't fast enough but was always OK engauging forwards. My 2004 Evinrude is as smooth as silk.
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Old 13 November 2008, 17:47   #9
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It's just a dog clutch, it's bound to clunk as it engages. Do it smartly to reduce wear. It'll be worse with a stainless prop than with an ally one.
Is that because the stainless is heavier ?
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Old 13 November 2008, 18:22   #10
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800 is a little high and yes 600 is more appropriate but I lowered mine to 550 and doing fine.
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