evinrude fisherman 5.5 restore

[catfishcarl99]

i have an evinrude fisherman 5.5 i believe a 64. been a while since i messed with it. anyway it ran last time i messed with it and idled great. idled for an hour in a tub with no issues.

the problem its got is 1 snapped off head bolt. should not be to much issue in drilling it out and getting it fixed. we idled it with this broke and no leaks or issues. the recoil ended up breaking {spring} i think. im gonna tear into it in the next few days. prob be having a few questions and some updates on the restore. its just sitting here and it needs to have a good home. i have no use for it and got it for free. PO didnt want it after the head bolt broke off. i messed with it very little {cleaned carb ect new plugs} and had it running in less than an hour. i want to restore it and sell it. 100% complete. it does have an issue with a few parts i remember but ebay seems to have about every thing ive ever needed at 1/3rd cost of retail.
so any thing you all can add shoot. ill get some pics up tomorrow.

my loss your gain $4000 lmao. trust me your getting a deal, e-mail for pics. i couldnt resist. been reading the craigslist tlc funny ads thread.

[catfishcarl99]

anyone know where i can get exploded views with part numbers? if the age is correct the one i use doesnt go back that far.ser# 5402B-E05974

[HighTrim]

marineengine.com will have your parts list

[HighTrim]

and yes it is a 64

[catfishcarl99]

thanks. ya i found some part numbers for things i need there. ebay has a few recoil springs. seen high though. need to look here and around.

[catfishcarl99]

well i got it out and fixed up a quick little stand for it. got out gas can and put a lil fuel in it. didnt touch a thing. pumped in fuel hit it with a shot of starting fluid and had it puttering within 10 min. ya think im gonna put a few bucks in it and use it or sell it. plans are to put a head gasket on it since ive had it off before and again. cheap enough. impellor. lil clean up paint fix any broken parts. think the lever on the lean screw might be hard to find and a shift lever. everything else is a ok. new decals. should about have it. the bolt had a nipple on it. the one broke off head bolt. sprayed it heated it but even with that the vise grips twisted off nipple. ill have to drill it out. cylinder wall feel great. nothing at all scored. pistons look good. nee decarbonized though.

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[catfishcarl99]

well the spring is broke.
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[catfishcarl99]

got the head bolt out. drilled it out. the old bolts were getting flattened out on the threads. went and got a 1/4" x 20 irwin tap and worked it in and out slowly with my 18 volt to sharpen the threads up. worked like a charm. the new stainless head bolt goes right in with fingers. got head decarbonized and shot a coat of gloss mbalck engine paint on it. carb coming off powerhead next. man having trouble finding the valve arm that goes on end of lean air screw. a black piece of plastic that holds the rod between the knob on cowl. its obsolete. did find a place that had 4 in stock. sent e-mail. came back as undeliverable

any ideas? part # is 0204 705 price is $2.38. but i cant find one. got a couple leads but im not holding my breath.
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[catfishcarl99]

before

after

got the impellor new head gasket and recoil spring on order and shipped.


this is the recoil plate. before.

after it was cleaned and re strung. waiting on spring now. should have by friday.

[catfishcarl99]

engine loosly togather waiting on head gasket and spring. also opened the carb up for a good cleaning.




cleaned off the top of lower and made a cork gasket for the top where bottom cowl sits. prob be ordering one for the top of lower where powerhead bolt on. pretty complex to make. i might try it though.


still have to get a coat of paint and clear on the lower.

[catfishcarl99]

got new plug boots on it today. oregon fron the farm store. boots and terminals. put a couple new plugs in it to. others were ok but $3. might as well. save others for spares.

got new fuel lines on it. like the color with the black.




test fit. made a cork gasket for lower cowl. i am making a gasket for the top of leg. if i fail ill order it. cant tighten much down till head gasket recoil spring and impeller come though.

the gears were in tip top shape. no filings pieces at all. no visible wear that was bad. clutch dog looked great. getting the gear housing ready to put back togather and fill with oil.

[Mas]

Looks like a fun project...keep it up! I do think that "metal plate" from your vid goes on front of the carb...I think?

Mas

[catfishcarl99]

your correct. put all that togather just a few hrs ago. it was the front of the silencer unit. got a piece of a briggs air filter to use as the silencing foam. had to replace the alum spacers with brass. lost one. had to go to the schems to remember how it went. thanks for replying too. felt lonely.


made the gasket from gasket material sheet for top of leg where powerhead bolts to. exaust/water



the three parts im waiting on all are tracked in illinois. should have them by friday. imp, head gas, and recoil spring. still looking for the valve arm on the air needle on carb. you can see in the above pic i made it from epoxy. it works but looks like crap and i would like to have orig. the hunt continues.

[Mas]

Looking good! To be honest, I think I would go with the factory "base gasket" for the powerhead. That's a pretty sensitve area. I'm not saying what you did will not work...just don't know how it'll wear. I wouldn't want the cork gasket to "squirt out" when the powerhead is tightened down. Also, while you're there, I'd replace the cork washer and o-ring in the carbon seal for the crank shaft seal assembly. Just be very careful not to break the carbon seal....they expensive!

Have fun,

Mas

[catfishcarl99]

thanks for the info. i actually didnt use the cork for the powerhead gasket. thats between the cowl and leg. i used a black fiber gasket material for that exaust one. this stuff.


look at that pic again. its the black one inside cork.

[Mas]

OK...gotchcha!

Mas

[catfishcarl99]

well you told me so lol. ya just had a pack of gasket meterial mixed media and thought ide save time and money. i put powerhead on and popped a couple bolts in it to see if i could get good idle out of it. still had a few things to do but got anxious. well after this i popped off powerhead to get the broken little shift pin out to get something of the same diam at the hardware store and the gasket was already coming apart. poopie. picked up this one tonight. well paid for it. should have it next week. http://www.ebay.com/itm/120911137745...84.m1439.l2649 also picked up a couple o rings so i could replace the one in the seal. wonder if i can find the cork washer easy enough. some things have been easy and some havent. got a neopreme one. think it would work?

[Mas]

I just bought the same gaskets/seals/o-rings yesterday at my local outbaord shop for my 6 hp for $8.00. They are out there...just gotta find the place that deals with slightly older stock. If iBoats does not carry them, try here:

http://www.marineengine.com/parts/vi...7853900001.htm

Look up the part numbers...then enter it. I've used them before....reasonable for "new" parts.

Mas

[catfishcarl99]

ys im glad i checked these too as the pin in the drive shaft. i had forgotton it. when the shaft moved to the center after i lined up powerdhead the spring had fallen down in leg. glad i didnt have everything done in there or the seal would be non existant. ya thats the site ive been using to get #ers and schems to put it back togather. thanks.

[catfishcarl99]

think im gonna do a camo job on the cowl. and clear it good over some vynil decals. something lik i did on this old file cabinet i turned into a pitsol locker.

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thinking about yellow in this decal
http://www.ebay.com/itm/110343716361...84.m1438.l2649

or maybe these. but not sure these will show well with camo??

http://www.ebay.com/itm/330622453561...84.m1438.l2649

[catfishcarl99]

should have my exaust/leg gasket tomorrow. get this thing done and back togather. got to get some stripper today and get the cowl ready to paint. got my decal ordered last night. went with the green pictured above. should sho well against the camo's dark colors yet not flash like the yellow i was gonna go with.

[catfishcarl99]

made the shift pin today and got the exaust gasket.


shift pin was made from a steel dowel pin. painted it to help prevent rust.



http://[IMG]http://i529.photobucket.....jpg[/IMG]

[catfishcarl99]

well after 1 1/2 hours at idle i shut it down. never died. after the first couple sputters when it was first started it never coughed again. this is whi i didnt tear into points timing or pistons ect... was sure it ran from before. so total i replaced.


head gasket
head bolts
exaust gasket
motor mount bolts
lower unit bolts and toothed lockwashers
new impeller
new recoil spring and rope
new driveshaft seal washer and o ring and roll pin
new plugs and plug boots
new fuel lines and in line filter
changed lower unit and cleaned and ge greased gears
replaced broken plastic shif pin with steel replacement
decarbonized pistons and head

just need to get it on a body of water to test it out. my boat doesnt have room on the sides for it. need to find a small john. would like to at least test drive her before i decide to sell it or keep it.

[nwcove]

great job catfish!! but why ya testing it in that 2gallon bucket when theres a pool right beside ya!!!

[catfishcarl99]

lmao. ya thought about that but i was afraid of an oil slick. thanks.
not sure what happened. this should have been in there. the first of the two running vids.