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Hi all from GB
Mac in now for next few months on river near worcester, GB.
How can I cure severe 'clunk' when engaging gear on my Tohatsu 50?
Annoying when close manoevering in marina!!
Thanks,
Max

PS Last boat was V8 petrol with NO clunk!!

Max,
My Honda 50 "clunks" fairly loud, also. This is my first outboard motor. It was my assumption, that's just the nature of the beast. Each spring when I change the lower end fluid, I clean off the little magnet plug (bolt end). It's always been just very fine metal dust - no large pieces that would show that "clunking" is overly bad for the gears. I could be wrong, but I'm not concerned about the "clunk".
FYI,
Dave "Jac"

Check that your motor is not ideling too high. My Tohatsu 50 goes in and out of gear smoothly when ideling slow, but not fast.
Jeff

I too had to deal with a loud clunk when shifting my Honda 50 in and out of gear (particuarly from forward to reverse). My idle was way too high.
This is not unusual for a new engine as it breaks in. I try to keep my idle at about 800-900 rpm. The engine shifts much more smoothly with the rpm in this range.
-Walt

Clunking
It's the Grinding that is bad. Dont slowly put an outboard into gear. If you go too slow it will grind and become worse over time. Also make sure your idle is 900 or below. I keep mine around 700. (Tohatsu) She has never stalled. But then I have a TLDI and the Computer maintains the RPMS at idle at either 700 900 or 1000. (what ever I choose). and there is no need for me to adjust it. Actually I'm going pretty good at the high trolling idle and it will go for hours on a gal. I'm slowly becoming a believer of this motor. I originally hated it when I compaired it to the quiet Hondas and 4cly/4stroke Mercs. In the spring the Hondas and a Mercs always took a few grinds to catch on. ... the TLDI started as quick as a fully warmed up motor.

But as far as clunking... Clunk ok Grind bad. Listen to other motors around you shift if you can. Dont forget to change the lower unit oil per MFG suggestions.

Bob Cardz explaination is exactly correct. We have the same outboard and are very happy with it. Just be deliberate when you shift.

Jesse