Tohatsu 3.5 2 stroke stuck in gear

[Enjay]

While replacing the sheer pin on my engine I decided to remove the cover holding the propeller shaft in place in the mistaken belief that the impeller was behind on this engine (Thanks YouTube!). On discovering it wasn't I popped it back, replaced the oil etc. I now find that while the lever and mechanism for neutral/forward still operate, the engine remains in gear.

I've tried adjusting the gear change shaft slightly at the bolt link through the rubber grommet but this hasn't helped. I'm reluctant to drain and reopen the gearbox/prop shaft before asking here if anyone has either experienced this or has suggestions about sorting out the problem.

Thanks in anticipation!

[spartacus]

I used to have one of these engines as an auxilliary. Suspect you’ve engaged the dog clutch on it somehow. It’s easy done. Had the same thing happen to me with Mariner 4hp when changing the impeller.

You shouldn’t have to drain the gear oil but you will probably have to drop the leg again to sort.

The gear linkage rod needs to remain vertical when reinstalling and check it’s in neutral, if it gets knocked when reassembling the leg it can go into gear, then there’s no adjustment at the gear lever on the engine. Pretty sure the water pump housing retains the dog clutch, there’s no separate stainless clamp or bolt to hold in position. You should be able to pull it up or push down to find neutral.

This video may help if you fast forward to the impeller section towards the end.

https://www.youtube.com/watch?v=1Zq6RkRuZFk

[Enjay]

Thanks for your insight Spartacus. I didn't actually drop the leg previously, just removed the plate which holds the prop shaft, together with the shaft itself. Once I saw that the impeller wasn't inside I simply popped it all back and bolted up and refilled.

I'll rewatch the video and order a new impeller then drop the leg and try to sort it whilst replacing the impeller at the same time.

Thanks again.

Nick