[The Rock]

I have a 1992 Evinrude 60hp engine that I have been working on. The carbs were gunked up from sitting a few months. I decided to pull them and give them a good cleaning. I didn't purchase a complete rebuild kit since the everything was fairly new already and the only local shop wanted $28 per kit! I was able to purchase the gaskets seperately for $5 and I am replacing all the fuel lines. The problem is the guy that rebuilt this engine last time, didn't put core plugs in the carbs. He used some sort of compound/sealer that is orange in color and hard. When I was soaking the carbs I tried not to expose those areas to the solvent. Well, it loosened some of them anyway and I've got a delima as to what to do next. I know what I should do is remove the compound and install the plugs. Even the shot plug is covered with it. As far as I know, the only way to get them is in the rebuild kits. Does anyone know what the previous mechanic used, or why other than being cheap? He has been working on the motors for 50 yrs. I was told at the parts store that in order to install the core plug, you need a "special tool", that usually means spending alot of $$ for something I won't ever use again. I know I can get the kits cheaper on the net just about anywhere, but was trying to avoid the extra cost and downtime. I would have to get 3 of them since all 3 carbs are this way. Any advice would be helpful.

Thanks,
Rocky

[wavrider]

Get the kits and install the correct plug.
that way you will not get stranded on the water due to some junk floating in the carbs.

They are not hard to install, I believe some people just tap them in the center and this flattens the plug out giving a good snug fit to the core.

Removal, some members have mentioned they drill a small hole in the center and remove them with a scribe or bent hook type tool.

[tashasdaddy]

i use a small ice pick, and just punch thru and pry them out, i use a short piece of 1/4" wood dowel to tap them in.

[Dhadley]

The orange sealer is probably Gasoila (sp?). That's the correct sealer.

[The Rock]

Is the only way to get new core plugs from the kit itself, or does someone know where I could get them seperately? I haven't taken off any of the sealant yet, for all I know there may be plugs installed and he put that stuff on over the top of them for some reason. After I cleaned the carb and blew out everything with compressed air I noticed fluid being forced out of one of the core plugs thru the cracks in the sealant. Is the core plug supposed seal the hole and prevent fluids from escaping? Since it is metal on metal with no gasket involved, I wouldn't think it would make a good seal? Thanks for the advise so far. I hate the thought of spending $60 on 3 kits for some plugs!

Rocky

[The Rock]

Originally Posted by Dhadley

The orange sealer is probably Gasoila (sp?). That's the correct sealer.

You spelled it correctly, and that does appear to be what it is. Should this be applied over the core plugs?

[tashasdaddy]

they are suppose to seal. sorry. he may have used old plugs.

[iwombat]

You can buy core plugs separate. Look up the part number at the brp site. I got a few from sea-way last time I went in. They're about $1 each.