I'm trying to install the water deflectors on my 1993 Johnson 25hp and they will not go in all the way to bottom out, they get stuck hard and if you push them of course they bulge as you push them, which makes matters worse. The deflectors are solid rubber and they are a larger diameter on one end than the other this is one of them Part Number 0335602 (28-0335602), it is [FONT="]Diameter .413" on one end, .371" on the other end x 1.06" length[/FONT]
The other Deflector is 28-0335603 (2 required) Diameter .413" one end, .360" other end x 1.81"ÃÂÃÂ length.
I tried spraying the hole and deflection with WD-40 as instructed in this forum. I tried with STP Oil treatment as instructed in the OMC Manual. No difference. It will go in till get gets to about the .390" diameter point and will go no further. No problem getting it in from the beginning .360" to the .390, but from there it won't budge.
Moreover, the depth required to bottom out the deflectors is much deeper than the deflectors themselves. The top deflector depth needed is 2.70" while the deflector is only 1.81" long. The shorter port side bottom deflector needs a depth of 1.7" and the deflector for that one is only 1.06". (The other bottom deflector, the starboard one requires 1.72 to bottom, and the deflector is 1.81, so that's the only one that bottoms out.)
Any experiences dealing with this from you pros?
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