NEWBIE * disaster on first day*

[UncleWillie]

Re: NEWBIE * disaster on first day*

When you get it back together remember it will run on muffs even with no impeller because the garden hose supplies the water pressure.

When running it in the water trough, right after starting, you should see water spraying out the exhaust bypass.
When on the lake, the exhaust headers will be warm, but not too hot to touch.
Check them before you cast off.

 

[sheboyganjohn]

Re: NEWBIE * disaster on first day*

And from someone that has done this in the past, also check the water hose between the drive and the boat inside the gimbal housing. When I smoked my impellor years ago due to trying to run in a garbage can instead of on muffs, I overheated again becuase this hose was cracked and only supplying minimal water to the engine. They were unrelated issues, but just check to save yourself a future headache.

 

[JerryIrons]

Re: NEWBIE * disaster on first day*

Britner don't beat yourself up over this, the same thing can happen to a veteran boater out on the lake when a plastic bag covers the water intake...probably the only difference is that once you get to know your boat you will hear the different sound the engine makes when it's not getting water coming through the exhaust (louder), and shut things down quicker. You are probably going to want to change out that impeller every other year just for the peace of mind. Some people even recommend every year. However you do it, put it on a preventative maintenance schedule. Also start a habit of watching all your gauges periodically when running the boat, and before you go out every time check fluid levels, and keep spare fluids on boat.

 

[achris]

Re: NEWBIE * disaster on first day*

...From the looks of your impeller housing, you may have been lucky enough not to have melted your water pocket (it's located in the upper)

From the look of the exhaust tubes around the elbows, I say he'd be very lucky if the water pocket cover doesn't leak now...
Either way, it needs to be checked.

 

[Britner]

Re: NEWBIE * disaster on first day*

Thanks again!

Your knowledge really shows with your replies & suggestions. This really is not like other forums!

I am a quick learner. After reading many of the articles on here, manuals posted on line (Don S) and videos (Chris) I think I have it covered!

I have now ordered the impeller kit (inc housing etc), water pocket cover, exhaust shutters (ordered 2, though they said I should only order 1?) Exhaust rubbers/tubes (Parts 1 & 5 x 2 on the 4" diagram) and should have the parts here tomorrow. I did also drop the engine oil, obviously the oil in the leg also and so that will be all new as well.

I won't spend any more on it as yet, just in case further damage occurred. If goes well, then I will replace anything else needed. I did see that the heat from the exhaust damaged the positive wire from the battery, which may have just prevented further damage! This will also be repaired.

I hope to get working on it Thursday.

I do get to learn about the motor & boat quicker than I expected. This I feel is a massive positive! I also have learned how fragile they can be, and how much care they need. Sounds like somebody very close to me.

Thanks again

Andy.
Kimberley BC, Canada.

 

[Don S]

Re: NEWBIE * disaster on first day*

A word of warning. DO NOT mess with that water pocket cover unless there is a reason to. The chances of getting the bolts out without breaking one is very slim, and the chances of repairing a broken bolt in there is even slimmer.
Especially if the boat has been in salt water.

If it's not seriously melted and warped, leave it alone. If you end up with a high rpm overheat, then it's time to look at it.

Post some pictures of it (bigger than your last images) so we can have a quick look. From the looks of the pump housing, not expecting any real problems with the water pocket.

 

[Britner]

Re: NEWBIE * disaster on first day*

thanks Don S.

I cleaned it up a little, does not look good to me! Though, maybe I'm looking at the wrong part?

 

[Don S]

Re: NEWBIE * disaster on first day*

Yeah, that doesn't look too good.

 

[Britner]

Re: NEWBIE * disaster on first day*

Didn't think so! I ordered it anyway, just in case. Rather be prepared than unprepared, like I was the first time.

 

[ktbarrentine]

Re: NEWBIE * disaster on first day*

Hopefully the bolts will come out nicely for you (fingers crossed). Be careful!

 

[achris]

Re: NEWBIE * disaster on first day*

The bolts are most likely seized in the plastic cover (maybe in the ali housing too, but we'll get to that). Once you're checked it and it is confirmed leaking and needs replacing... put the housing in a stout vice, upside down, then take a small blow torch and a screwdriver and break up the cover and get it all off the bolts. Don't try a spanner at this stage. Once all the cover is gone, heat the bolts and the housing up to try and dry out any moisture in the threads. Once it's cooled down, use a long drift and a decent size hammer and give the bolts some sharp hits. We are trying to loosen them up as much as possible before using a spanner. You might like to throw a quart or so of penetrating oil on them too... and let it sit for a few weeks. (Just kidding, overnight would be enough.) The likelihood of breaking at least one of them is quite high, and breaking all 4 is very possible. If you manage to get one out, you have a good starting point. When we had our shop I had a template from a piece of 1/4" plate with the holes drilled. If we managed to get one bolt out and the others broke off, we'd screw the plate down with a new bolt and use that as a drilling guide. Trying to centre drill broken off stainless steel bolts in an inaccessible place inside an aluminium housing without a guide has about a 1 in 10,000 chance of going well... Most of the time the drill will slide straight off the top of the stud and into the ali housing... Not what you want. You're also going to need some LONG drills, or a drilling machine with a very small head and a long handle. Once you have them all out lol helicoil them! (should have been done in the factory :facepalm

At this point, about all that's left to say it, good luck.... and keep us posted.

Just one more thing.. Once you're done, replace the seal in the hole next to the cover. It's copped as much heat as the cover got.

Chris.......

 

[Mischief Managed]

Re: NEWBIE * disaster on first day*

The amount of support and advice here is just awesome. You guys rock.

Good luck Britner!

 

[Britner]

Re: NEWBIE * disaster on first day*

Mischief Managed, I totally agree. I think I'm gonna try and re-assemble everything apart from the plastic housing. Then if things aren't quite right, maybe try then! I think there is a better chance of winning the lotto than causing more damage to my motor!

 

[Britner]

Re: NEWBIE * disaster on first day*

UPDATE!!!

So far I have replaced the exhaust tubes, the exhaust flappers, the impeller, casings & gaskets etc and still have issues. I have been all over the forums, the manual so on and so forth.

I am currently working on trying to get the lower leg installed correctly. When I dropped it off, I did not have it in gear, either forward or reverse. I had it in neutral and dropped it. With it off I can find drive (forward) and neutral, not reverse. This with the shifter shaft. Every time I connect the upper and lower parts, I cant get the propeller to freely rotate. I am stuck. I am wondering if there is a problem with the shifter shaft, or am i just missing something here?

I am really learning what to do and what not to do.

Andy.

 

[ktbarrentine]

Re: NEWBIE * disaster on first day*

Sounds like it is time to place the shifter lever in FWD, remove the upper from the bell housing, put the upper and lower together (correctly) on the bench (where you can do a "good" thorough pressure test), then play with the shifter shaft (intermediate shaft) in the various positions (Rev-Neu-FWD) and make sure you are getting the proper response from the drive (prop locking CCW while shifter in FWD, locking CW when in Rev, free-wheeling in neutral), then lock it in FWD as discussed earlier, fill it with oil, and reinstall it on the bell housing. (after a good alignment check).

Good luck!

 

[Britner]

Re: NEWBIE * disaster on first day*

Thanks.

Ok, I will drop the upper off and fix on a bench. I have attached a small video, just to see if this looks right. I said it could go in Neutral, but right now I cant get it out of drive. Also the shift shaft spins freely when slightly lifted, and spins without lifting, albeit with some friction. Is this something that I should look at before carrying out the above (ktbarrentine's fix)?

SORRY, Cant upload video!! Here is a photo

 

[achris]

Re: NEWBIE * disaster on first day*

If you still have the upper on the bell-housing, connecting the lower is really simple. All I do is out the control lever full forward, then turn the shift shaft in the lower housing full clockwise (while turning the prop slowly CCW to ensure full engagement of the dogs.). If you are putting it up with the drive tilted up, then the selector in the housing will naturally fall towards the FORWARD gear position. You may need to turn the drive-shaft a little to line the splines up. Do that by turning the prop CCW, NEVER CW or it'll push out of FORWARD...

Don't forget the little rubber washer and the slightly larger SS washer on top of the lower shift-shaft...

Chris.......

 

[Britner]

Re: NEWBIE * disaster on first day*

Thanks Chris! I have just got in from taking the upper part off! It makes sense what you say.

Going back to the shift shaft, again it freely turns, does not let me select Neutral or Reverse, then when I did re-attach the lower to the upper again it stayed in drive.

I have put some pics here to show you what I have. After looking at these pics, is there anything else that you guys would do? The water pocket does not look to healthy! I would like to try and re-assemble shortly. This boat was purchased thinking it was running, but is turning in to a project!!! I don't have year round boating like many of you guys, I only have about 3 months. Would prefer to not have to work on it for 3 months.

 

[ktbarrentine]

Re: NEWBIE * disaster on first day*

Wow! looks like you have some pretty serious issues with your water pocket cover and your shaft seal(s) next to it. Also, in photo number 1, you are missing a screw in your pump housing.

 

[Britner]

Re: NEWBIE * disaster on first day*

Thanks! I'm really happy that I didn't get it on the first time, as I didn't see the damage as close up until I dropped the upper section off. I ordered a water pocket cover and the shop said I was wrong, I didn't need it or they didn't know what I was talking about!