New throttle lever too tight to seat fully

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   The chrome ring that controls the shift lever lockout was completely worn out on my original throttle/shift lever, so I got a new assembly as part of the restoration of 96 Sport. 

I’ve had quite a problem getting it to seat fully. The spline hub on the shift lever doesn’t really want to sit fully on to the splined post on the boat. At first I just thought I wasn’t getting the setscrew tight enough but then I realized it’s not pushing in deep enough. I actually took a rubber mallet and tried to tap it in two weeks ago. I thought that I might’ve had some success. It still didn’t feel like it completely seated but the chrome lock ring didn’t turn in everything felt snug. Then yesterday while out in the boat the lever became loose again.

What do I need to do here? Do I just use more force to top it in? I’m surprised it’s tough to get it to seat properly. 

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Canuck-Surfer Members Profile Send Private Message Find Members Posts Add to Buddy List Senior Member Joined: September-14-2019 Location: Ontario, Canada Status: Offline Points: 220	Post Options Post Reply Quote Canuck-Surfer Report Post Thanks(0) Quote Reply Topic: New throttle lever too tight to seat fully Posted: August-21-2021 at 10:07am
	The chrome ring that controls the shift lever lockout was completely worn out on my original throttle/shift lever, so I got a new assembly as part of the restoration of 96 Sport. I’ve had quite a problem getting it to seat fully. The spline hub on the shift lever doesn’t really want to sit fully on to the splined post on the boat. At first I just thought I wasn’t getting the setscrew tight enough but then I realized it’s not pushing in deep enough. I actually took a rubber mallet and tried to tap it in two weeks ago. I thought that I might’ve had some success. It still didn’t feel like it completely seated but the chrome lock ring didn’t turn in everything felt snug. Then yesterday while out in the boat the lever became loose again. What do I need to do here? Do I just use more force to top it in? I’m surprised it’s tough to get it to seat properly.
	1996 Sport Nautique GT40 EFI

8122pbrainard Members Profile Send Private Message Find Members Posts Add to Buddy List Grand Poobah Joined: September-14-2006 Location: Three Lakes Wi. Status: Offline Points: 41040	Post Options Post Reply Quote 8122pbrainard Report Post Thanks(0) Quote Reply Posted: August-21-2021 at 11:50am
	Matt, The lever is a zinc die casting. I wonder if there was a burr at the parting line of the splined bore that's interfering with it easily sliding on the shaft. I'd pull the lever off and check if you can see anything in the spline bore.
	54 Atom 77 Tique 64 X55 Dunphy Keep it original, Pete <

Canuck-Surfer Members Profile Send Private Message Find Members Posts Add to Buddy List Senior Member Joined: September-14-2019 Location: Ontario, Canada Status: Offline Points: 220	Post Options Post Reply Quote Canuck-Surfer Report Post Thanks(0) Quote Reply Posted: August-21-2021 at 11:02pm
	Some else suggested today to use a bit of grease. I tried that tonight and it slid fully on with a little tapping from the rubber mallet.
	1996 Sport Nautique GT40 EFI

Canuck-Surfer Members Profile Send Private Message Find Members Posts Add to Buddy List Senior Member Joined: September-14-2019 Location: Ontario, Canada Status: Offline Points: 220	Post Options Post Reply Quote Canuck-Surfer Report Post Thanks(0) Quote Reply Posted: July-10-2023 at 10:16pm
	Hey guys, I’m resurrecting this thread. I’m about to pull my hair out. This problem has persisted since I put the new shift lever on. Last summer I would have to reinstall it every few weeks. It’s progressively gotten worse and now the liver is falling off every few days, is this not a common problem? The lever is definitely not seating is deep is it should. I’ve taken it apart and looked at it. I can see where the Allen keys that screw is supposed to hold it on. The lever is not seeding that far down. should I get a C clamp and try to press it on or is this love or just have a manufacturing defect?
	1996 Sport Nautique GT40 EFI

New throttle lever too tight to seat fully

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