kick start shaft replace 86 200x Hard or Easy???

[1972mercury]

I recently bought a 86 200x and it looks it needs the shaft replaced is there something else I could use and if so how easy is it to replace do you have to split the cases or just take the right case cover off and somehow slide it out and put the new one in I'm not really sure nver done something like this yet so what do you guys think???

[twitch101]

its a split cases job and i believe only 200x parts work but im unsure. its a good idea to get the gears undercut to fix the slipping problem.

[Dirtcrasher]

The 86 IS NOT a case splitting job. Those shafts snap off at the edge of the case because they are 3mm's smaller than the 87 shaft.

Drain oil, pull the clutch cover, remove the 3 oil filter rotor screws (they will strip, use good screwdriver) clean rotor and screen in the lower portion of the case, remove the crank nut (LH threads!!!!), unfold the clutch basket retaining washer, remove the nut and remove the whole clutch (washers get stuck to the back, do not mix up thrust washers) now put vice grips on the shaft and roll it clockwise until the return spring comes out of the notch in the case. Make sure all the gears and dots line up on the new one and angle it in while you roll it forwards with a good kicker to reset that return spring. If you do it wrong, it will have to come apart again.

Some people leave the oil in and lay it on the side. You do not need the special 4 pronged nut remover for the crank or clutch. You will need an air impact to get the basket off, put a penny in the gears will get the crank LH thread off. Never use anything to hold that basket such as a screwdriver, you will break a finger off......

Piece of cake, but don't you dare touch it without a manual next to you!

[twitch101]

as always DC is on top of his game. good luck and dont put yourself into more trouble.

[250rRoostmaster]

Would dirtcrashers way work on an 84' 200x??? I think my kicker gears are getting pretty shot and i will be needing to do this soon...

[dougspcs]

DC is the shiznit!! Talks a guy thru an expensive repair!!

Don't forget your 'thank you' mercury like your mom taught you...

Replaced the clutch in my 350x a month back..5% manual, 95% word of DC!!

[Jim mac]

IVe never done this before last friday. just like it was told to you. Only thing when you go to pull the shaft out. put the kicker back on and turn it forward like kicking it and it rolls right out.
then when you put it back together, make sure the punch mark on the shaft is straight up slide it in work the spring hook around the plate, rotate it backwards so it hooks, turn the shaft forward and about time the punch mark is straight up, it'll fall right in.
My 87 has a 86 motor in it. the kicker was junk, fortunately the guy gave me the original 87 motor and kicker (motor has a bad rod bearing and piston) so I swapped the 87 assembly into the 86 motor because I couldnt find a 86 kicker.
jim