ANSWER:
After 6 weeks of back and forth with the Merc Dealer (not too happy with)...
It looks like the $5 water tube seal was probably the culprit. (part: 43023 2). This from the output of the pump to the motor. It looks like the L/U was put up a little offline at first and part of that seal folded over...making it look like an oval. (now to see if dealer will try to charge us for a part they put on wrong..may post on that later if they try). It was either not pushing enough water or not enough pressure to open the poppit.
LESSONS LEARNED
1.) As mentioned by everyone...put in a darn water pressure gauge. This would have let us know we had an issue as soon as it was started. Our gauge goes in this fall.
2.) The temperature sensor for the gauges on Mercury Saltwater (125 anyway) is useless. It is mounted on the flushing line that has no water going through it. It showed 120 when the alarm was going off at 190. May consider moving this.
3.) Should have tried running it w/o the poppit as part of the search.
4.) Someone else posted that exhaust gasket failure can give these symptoms. (not our issue but tossing it out there)
BACKGROUND:
2003 125 Mercury Saltwater carb. Bought in 2008 and ran great in 2008. Had Mercury dealer change "all" parts of cooling system since they were original. Pump, t-stat, poppit were changed.
Got boat back and alarm when off within 30 seconds of passing 3000 RPM but never below 3000 RPM. But, the pee water was warmer than last year. Changed alarm switch with no effect (the warning was real, not a bad sensor). Also dropped from 21" prop to 19" prop to get more RPM with less load. Hole Shot was much better but motor was still doing exactly the same.
Also noticed some exhaust bubble coming out of the lower unit to cowling seam (where you take it apart to get to the water pump). Bubbles were only in back...in the exhaust section. Dealer probably warped it a little using a torch to get lower unit off.
Ran 'er yesterday. No alarm, pee water is cooler. (also fewer bubbles leaking out...which supposedly isn't related). Lost 7 weeks to a $5 part.
the seal is part #49 in this link.
http://www.sterndrive.info/mercury-outboard-parts/60hp_to_125hp_component_layout.html
HOPE THIS HELPS...
After 6 weeks of back and forth with the Merc Dealer (not too happy with)...
It looks like the $5 water tube seal was probably the culprit. (part: 43023 2). This from the output of the pump to the motor. It looks like the L/U was put up a little offline at first and part of that seal folded over...making it look like an oval. (now to see if dealer will try to charge us for a part they put on wrong..may post on that later if they try). It was either not pushing enough water or not enough pressure to open the poppit.
LESSONS LEARNED
1.) As mentioned by everyone...put in a darn water pressure gauge. This would have let us know we had an issue as soon as it was started. Our gauge goes in this fall.
2.) The temperature sensor for the gauges on Mercury Saltwater (125 anyway) is useless. It is mounted on the flushing line that has no water going through it. It showed 120 when the alarm was going off at 190. May consider moving this.
3.) Should have tried running it w/o the poppit as part of the search.
4.) Someone else posted that exhaust gasket failure can give these symptoms. (not our issue but tossing it out there)
BACKGROUND:
2003 125 Mercury Saltwater carb. Bought in 2008 and ran great in 2008. Had Mercury dealer change "all" parts of cooling system since they were original. Pump, t-stat, poppit were changed.
Got boat back and alarm when off within 30 seconds of passing 3000 RPM but never below 3000 RPM. But, the pee water was warmer than last year. Changed alarm switch with no effect (the warning was real, not a bad sensor). Also dropped from 21" prop to 19" prop to get more RPM with less load. Hole Shot was much better but motor was still doing exactly the same.
Also noticed some exhaust bubble coming out of the lower unit to cowling seam (where you take it apart to get to the water pump). Bubbles were only in back...in the exhaust section. Dealer probably warped it a little using a torch to get lower unit off.
Ran 'er yesterday. No alarm, pee water is cooler. (also fewer bubbles leaking out...which supposedly isn't related). Lost 7 weeks to a $5 part.
the seal is part #49 in this link.
http://www.sterndrive.info/mercury-outboard-parts/60hp_to_125hp_component_layout.html
HOPE THIS HELPS...
