Katanna

iTrader: (1)

I have had that happen before when doing alignments. Just for the hell of it, put the alignment tool in and hit it with a rubber mallet side to side and top and bottom. Sometimes the rubber can take a set and needs a little help to center itself. Give it a few good whacks.

Steve

TomZ

iTrader: (2)

Wish that would have worked... believe me I tried everything. Looking down through the bearing you could watch the coupler make a wobbling spiral.... definitely bad.

SB

iTrader: (1)

You ran it with the alignment tool in ?

TomZ

iTrader: (2)

It was a proper test based on the circumstances. The coupler was already screwed. If you had seen the wobble while turning over the engine, you'd understand.

Tinkerer

That sux

TomZ

iTrader: (2)

Yup.

Hey, at least I'm getting really good at taking this thing apart and putting it back together!

GLENAMY 242SS

iTrader: (1)

Tom, are you using the tapered centering screws for install alignment? here is a Service Bulletin for install. Your journey is starting to sound like Scott Jourgensen's luck.
All the best.
http://www.marinemechanic.com/merc/d...ange_EN_11.pdf

TomZ

iTrader: (2)

Yes, I made sure the coupler was centered.

I have that very link saved in my favorites.

TomZ

iTrader: (2)

Just an update... and it's a good one!

Got a replacement coupler from Sick Stinger (many thanks Mike!) as well as a new replacement from Amazon/Sierra (that was a surprise!). I installed the original flywheel (had a new ring put on it), aligned the coupler to the flywheel, installed everything in the boat, got her perfectly aligned, and I'm happy to say that the set-up has about six hours on the clock with no drive issues. In fact, I've used the boat more in the last two weeks than I had the entire summer combined!

Just want to say thanks to everyone for all the help! And a huge thanks to Sick Stinger for standing behind his parts! That's huge in my book.