Can't Get Water Flow in Evinrude 68 (Model 6803R)

BillyBoating

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The motor on this runs fine, but when I started it there was no sign of any water out of the tell tale (the approx. 1/2 inch hold about 12 inches down in the back).
I read on Leeroy's site (I'm assuming most of you have seen it), and in other places, that water doesn't come out of this hole until the engine has warmed up (thermostat opens) and the engine is in forward gear, as this engine needs the prop push against the intake to feed the water.
Well, mine wasn't spitting any water at all, even when revved up in forward gear. I made sure the water level was well above the intake.

So, I did the first thing everyone suggests, and replaced the impeller. The one in there looked very good, but I replaced it anyway, cleaned things up, and reassembled. Still no water.

So, I took off thermostat cover. Thermostat had grass / muck in it, so I took it off and cleaned it up. Also cleaned up all the holes in the thermostat housing. None were blocked, but they were a little dirty so I scraped them out. Reassembled, started, but still no water out of telltale.

Took thermostat cover off and saw that there was no sign of water in there. That is to say, the "tray" or flat area inside, was dry.

Leaving thermostat cover off and thermostat out, started engine and put in gear. Expected to see water shoot up into the air out of thermostat housing. No such luck. A little dribble was about it.

So, I'm seeking help here. If someone can help me out either:
1) ideas to check next (a friend suggested maybe blown head gasket?)
2) how water flows in the thermostat area. If you look at the picture I've attached, I numbered the holes in the housing. 1 and 2 are obvious. 3 and 4 are covered by the thermostat, but let's say 3 is the small hole at the top of the thermostat hole, and 4 is the hole further down. In what order does the water flow between these 4 holes? That is, it comes in through the intake, then comes in what hole, goes out which hole, and when thermostat opens what changes.

Sorry for the long post.
 

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F_R

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First things first--have you got it deep enough in the water? "Above the intake" isn't deep enough. The water pump must be submerged a couple of inches before starting the motor.

With all due respect, that is pure BS about not pumping till the thermostat is open and in forward gear. It should pump ANYTIME it is running, hot or cold, fast or slow, in gear or in neutral.

Water comes up 2 and 4 and exits out 1. That area looks nice and clean now.

EDIT: Well, OK, a few motors don't pump very much till the thermostat opens, but that is not the case with this one. Didn't mean to offend anybody.
 
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BillyBoating

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Thanks for the input. The water level was about where I'd expect it to be when the motor's hanging off my transom, so I thought that's the level where it should run. Not sure what I can use to get it much deeper, but I'll look around.

Just so I'm clear, if water comes in 2 and 4 and exits out 1, what is hole 3 (the one closest to the top of the thermostat hole) for?

I'm not sure if it matters, but I poured some water through hole 1, and it ran out the telltale as well as out the small hole just above the prop. I removed the thermostat and poured some water in that hole as well, and it ran out through the small water vents on the side of the lower unit (the vents that are supposedly for water intake when going in reverse).
 
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BillyBoating

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Okay, I put it under up to the big bracket/brace just below the telltale. I get water coming out, but nothing like a stream. It's just sort of spitting. So I took off the thermostat cover again, and water was just barely bubbling up to that level. On top of that, it looks like some exhaust was actually coming into the thermostat housing. Is that normal? Blown head gasket possible?
 
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racerone

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Well some exhaust bubbles could be pumped up through the motor !----Test this motor on a boat.---And yes any time this motor is running the water pours out with the exhaust.----Leroy is mistaken on this topic and this particular motor !
 

BillyBoating

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Thanks racer one. When you say that water comes out with the exhaust, am I correct that most of the water that circulates is pumped out under water with the exhaust, just above the water intake, and only a little comes out the exhaust from the telltale?
 
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racerone

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Some of the water comes out with the exhaust relief up on the housing.----The rest goes out down below.---Simply put when running this motor the water must be 6" or more above the pump.---Covering the intake with water is not good enuff.
 

BillyBoating

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No Title

This is how high the water was when I last ran the motor.
 

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BillyBoating

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Wow. I gotta find me a deeper barrel then. I can't really run it on the boat as I'm not near the water and it's for an inflatable that's currently deflated and in the basement. It seems like it won't sit much deeper than this once it's mounted, but without being on the water as you say I can't be sure.
Thanks for your help so far. I'm frustrated to no end.
 

racerone

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I know these motors !---Have had the pistons out of 7 of these motors and re-assembled them in the last 2 winters alone.--Great motors, simple and easy to maintain.-If in good condition now it will last another 50 years.--Easier to get most of the parts than some much newer motors too.
 

BillyBoating

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Believe me, I don't in any way doubt you know these motors. I'm just letting you know what I've been going by so you don't think I haven't been trying to do it right. About the only good I can say has come of this is I've had to learn a lot about this motor, which in the long run will serve me well, even if only to pass on painful lessons learned to my son (who I hope to take fishing using this motor one of these days).
 

BillyBoating

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Okay, this time I put it in right up to the telltale.
Started it, and still got just some spitting from the telltale, with exhaust. See pic.
Took off thermostat cover and pulled thermostat. Got bubbling up top of hole 2, with a little trickle coming in at hole 4.
Video of it is here: https://youtu.be/1FE-Q7HU1Es
Thoughts? Next step?
Thanks
 

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racerone

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The water tube ?-----Did it stay in the exhaust housing or did it stick in the pump ?---If it stuck in the pump did you install it in the grommet of the exhaust housing first ?
 

BillyBoating

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The water tube stayed in the leg when I dropped the lower unit to change the impeller.
I was just running it some more (waited for it to cool some, and oddly enough there seems to be a little bit better flow. Water is spitting in to the air out of hole 2, and trickling a little faster into hole 4.
Should water be just shooting out of hole 2, like 6 inches into the air, or 1 inch, or...?
 

racerone

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Do not know what holes you are talking aqbout.---Never had a problem getting one of these motors to cool properly.--There are 2 gaskets that will fit between the block and the exhaust housing.-Perhaps your motor has the wrong one.----I can not see that where I am so only guessing.
 

BillyBoating

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I put the thermostat cover back on and ran it. It looks to be spitting as much water as I see similar motors doing on other YouTube videos, but it seems to be very hot. Of course, I have no idea if very hot is too hot.
Here's the last vid, first in neutral than in gear. https://youtu.be/Wb1JBmp7hes
 
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