I recently got my 2004 225 HPDI back after having the powerhead replaced for the second time. It took the dealer 5 weeks to complete the repairs and then I had to take it back 2 more times because it wasn't running right. Once they found that one of the bolts on the air intake manifold wasn't tightened, that made it idle rough, and the other time a ground wire wasn't making a solid connection, causing the fuel pump to cut on an off. My relationship with this dealer is a little strained to say the least. I am happy that for now it is at least running good. My problem, however, is a knocking sound every time I put it in gear. Once I accelerate it seems to go away or maybe I just can't hear it. I've mentioned it to the dealer several times but they haven't offered to do anything or give me any suggestions. The sound is almost like what you hear when someone trys shifting an older outboard into gear and the gears knock before locking into place.
I've been running outboards for 30 years but am not mechanically inclined. My guess would be something loose in the shift linkage or the gears since it only happens when I put the engine in gear. The dealer did drop the lower unit during the powerhead repairs to replace the water pump and, by the way, I was able to squeeze in a tube of gearcase lube after I got it back. Any suggestions on what this noise might be?
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