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 Post subject: 1986 25hp Mercury XD
PostPosted: 13 Apr 2018, 18:06 

Joined: 21 Jan 2017, 18:26
Posts: 8
Hi guys, I was hoping someone could help me out with trying to get the twist grip off to replace the stop switch. I pried the rubber handle off and removed the set screw but I don't want to tug too hard on anything before knowing what needs to be done. The twist grip has to come off somehow.



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14' Mirrocraft 1986 25hp Mercury
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 Post subject: 1986 25hp Mercury XD
PostPosted: 13 Apr 2018, 20:49 

Joined: 29 Jun 2016, 19:36
Posts: 559
Location: middle of NC
http://www.marineengine.com/parts/mercu ... bly-manual



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 Post subject: 1986 25hp Mercury XD
PostPosted: 14 Apr 2018, 07:51 

Joined: 21 Jan 2017, 18:26
Posts: 8
water bouy wrote:
http://www.marineengine.com/parts/mercury-outboard-parts/25-2-cyl/5705532-thru-6416712-usa/steering-handle-assembly-manual



I have looked at this schematic but still doesn't show how to actually remove the twist grip. I have gotten to the point where the set screw has been removed but I am stuck there. I do not want to damage any linkage by pulling too hard and nothing is budging.



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 Post subject: 1986 25hp Mercury XD
PostPosted: 14 Apr 2018, 10:57 

Joined: 25 Oct 2017, 18:48
Posts: 18
Shanny, The steering handle assemble must be loose or removed from the motor.
the wiring needs to be disconnected from motor.
once this is done remove the rubber grip. remove set screw under grip.
you should be able to remove stop switch now. To further disassemble the
steering handle there is another set screw near the pulley on the handle.
Once this is removed the inner shaft may be removed from the outer shaft.
Good luck!


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 Post subject: 1986 25hp Mercury XD
PostPosted: 14 Apr 2018, 16:43 

Joined: 21 Jan 2017, 18:26
Posts: 8
Carphunter wrote:
Shanny, The steering handle assemble must be loose or removed from the motor.
the wiring needs to be disconnected from motor.
once this is done remove the rubber grip. remove set screw under grip.
you should be able to remove stop switch now. To further disassemble the
steering handle there is another set screw near the pulley on the handle.
Once this is removed the inner shaft may be removed from the outer shaft.
Good luck!



Thank you, I will try this out!



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14' Mirrocraft 1986 25hp Mercury
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 Post subject: 1986 25hp Mercury XD
PostPosted: 16 Apr 2018, 11:40 

Joined: 21 Jan 2017, 18:26
Posts: 8
So I tried again with no luck. After removing the set screw on the twist grip, it still feels like it is very securely attached to the tiller arm somehow and not by just wires.



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 Post subject: 1986 25hp Mercury XD
PostPosted: 16 Apr 2018, 21:32 

Joined: 25 Oct 2017, 18:48
Posts: 18
Remove the tiller arm completely, Remove set screw from tiller handle near the pivot, should com apart. Use
penetrating fluid if not easy. Also get a service manual, it will help sooo much in the future.


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