I replaced the water pump in my 115 and reinstalled the lower unit with no issue - almost, the engine would not go into gear (common problem), yes, I did not align the gear shift with the receiving shaft. Anyway, that has turned out to be the least of my problems - now when I attempt to re-insert the drive shaft it will not go the last 3-4 inches - have tried everything, rotating the unit, rotating the flywheel, engagine the ignition slightly. I inserted a 1/2 rubber tube all the way to the top (approx 25" - same length as drive shaft) with no problem. It appears as though the drive shaft and oil pump gears are not aligning with the teeth on the shaft - considering removing the power head to inspect from above - but not happy about the thought of doing that - any suggestions?
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2002 115HP 4 Stroke Lower Unit
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