Johnson 9.9 copper water tube troubles

[slampoud]

I have a Johnson 9.9 sailmaster longshaft 1988 outboard. I noticed that there was no water coming out of the tattle-tale (or tell-tale, depending on who you ask), so I took the thing apart to make sure there's nothing wrong with the impeller. <br /><br />While the impeller turned out to be fine, I found that the copper tube that carries water from the impeller to the engine looks funny. <br />First of all, it's bent -- not enough to stop the water from flowing, but it doesn't go straight up either. I'm guessing that's not supposed to be the case, but does anyone know for sure?<br /><br />Second, the bottom part of the copper tube came out of the impeller fine but the top will not come out of the exhaust section. It goes up and down in its shaft, so it's not attached to the engine at the top, but it refuses to come out. Is there something at the top of the thing (a gasket maybe?) And shouldn't the top be attached to an inlet on the engine? <br />It seems that the way things currently are the impeller will shoot water up the copper tube and then the water will come out the top of the tube and run back down through the housing of the tube and into the leg of the motor never actually reaching the engine. <br /><br />Thanks for any help!

 

[DHPMARINE]

Re: Johnson 9.9 copper water tube troubles

Hi! The copper tube on all the 9.9 and 15 motors I've seen are straight.Also no up and down play on the tube.<br /><br />Perhaps the gearcase was installed with the tube misaligned,bending it.<br /><br />Also perhaps overheating has damaged the grommet/washer at the top of the tube.<br /><br /> By the way,the tube does not pull down.You have to remove the powerhead and lift it out from the top.<br /><br />DHP

 

[Joe Reeves]

Re: Johnson 9.9 copper water tube troubles

That water tube does have a slight bend to it, not severe but not perfectly straight. As per DHPMarine's reply, it should not move up and down.<br /><br />Using a plain ruler, with that tube pushed upwards, measure the distance from the bottom of the tube to the lower portion of the exhaust housing surface (the housing the tube is within). Then apply that measurement to the water pump assy grommet to see how far the tube would insert in the grommet. That should tell you if it (the tube) is bent or not.

 

[Vic.S]

Re: Johnson 9.9 copper water tube troubles

My experiences are with the 6 hp but it all sounds very similar. The copper tube is not dead straight but has a slight double bend because the pump discharge and engine inlet are not exactly in line with each other. <br /><br />The problem is almost certainly due to the grommet/sleeve at the top having failed. As DHP says you have to remove the powerhead then unbolt the assembly that carries the pipe from it.<br /><br />My problems were cased by corrosion between this and the rubber grommet squeezing the grommet over the top of the tube and cutting off the water flow.<br /><br />Make sure you note how things are assemled as you go especially the parts of the ignition system.<br />When you reassemble make sure the copper tube is not touching any alloy parts.

 

[slampoud]

Re: Johnson 9.9 copper water tube troubles

Well, I was hoping I wouldn't have to remove the powerhead, but sounds like I need to get to the top of that tube. <br />Does anyone know if the grommet at the top is something one can buy at West Marine or whether it's the kind of part that will need to be ordered? I'm guessing the old one may need to be replaced.<br /><br />Thanks for all the suggestions so far!

 

[umblecumbuz]

Re: Johnson 9.9 copper water tube troubles

To add to the above, the copper tube in your engine has what is known as a 'set'. Two bends offset the tube, but the top and bottom lengths of the tube should align on the same axis.<br /><br />As has been said, the tube is fitted into the exhaust tube (squarish shaped boxy tube, with flange at motor end held onto powerhead by four bolts). Once the four bolts are removed the exhaust tube can be pulled away from the powerhead, and the copper water pipe can then be lifted out of the exhaust housing. There should be a rubber sealing grommet, which both seals the waterway and holds the tube firm against the powerhead. If the tube feels loose before this disassembly,then the grommet has failed, and so has the integrity of the water circuit. Gotta be renewed, or else ...<br /><br />Straightforward and satisfying job. Clean everything, then clean everything, then clean everything, and it will last forever! Lovely motors!<br /><br />Ciao.

 

[Jack Shellac]

Re: Johnson 9.9 copper water tube troubles

Before you pull the powerhead, make sure the passages under the exhaust covers are clean. The water from the pump on these models enters the powerhead at the top of the covers and the pisser taps off the bottom. There are small passages under these covers that clog fairly easy, particularly in salt water. There are two covers [one under the other] and you'll need two gaskets. It's not all that hard to pull the powerhead on these motors, but this may save you that trouble. As the other guys said, these tubes do have a slight offset bend.