Exhaust Cover Plug won't come out - 93 Evinrude 40hp

[Mark42]

I'm installing a water pressure gauge and the plug in the exhaust cover stripped (it comes out with a hex wrench and the wrench spun in the plug.) The plug did turn about 1/4 turn before seizing up. <br /><br />I'm thinking of just drilling out the plug and installing the brass fitting. Or should I try using an easy out first? <br /><br />How much clearance is there if I drill it out?<br /><br />Being 13 years old, I figure the plug is fairly well corroded in place from the inside. It looks fine from the outside.<br /><br />Any suggestions are welcome.

 

[Silvertip]

Re: Exhaust Cover Plug won't come out - 93 Evinrude 40hp

Leave the plug in and "Tee" into the tell tale line.

 

[fireman57]

Re: Exhaust Cover Plug won't come out - 93 Evinrude 40hp

Ooooohhh, great suggestion upinsmoke! If the original ain't leaking your suggestion is perfect.

 

[Mark42]

Re: Exhaust Cover Plug won't come out - 93 Evinrude 40hp

That thought had crossed my mind, but I don't think it will yield the same pressure reading that it will get from tapping into the exhaust cover.<br /><br />The Teleflex gauge instructions are very clear on how to connect. The instructions indicate that the plug should be removed, and if there is no plug, to drill and tap a hole where the plug normally is.<br /><br />If the same results could be had by connecting to the tell tale, then why wouldn't the instructions say connect to the telltale?<br /><br />EDIT: <br /><br />I went to the Teleflex website and found this info under "Teleflex Technical Product FAQ's":<br />(bold by me)<br /><br />

The pressure gauge adapts to the engine in various ways. Teleflex provides a kit that includes the gauge and all necessary fittings to adapt to most U.S. built engines and some imported engines. Access to water pressure may be at the overboard discharge hose, a water by-pass hose, or a fitting directly into the cylinder head cover (some offshore engines require a metric threaded fitting that Teleflex does not supply and therefore does not recommend the kit in these applications. Teleflex does have available bushing 61886P for Yamaha). The kit may have more fittings than are necessary for a particular application. However, the extra parts may come in handy for some other job. <br />

So it looks like Upinsmoke has the right advice! Now watch, the plug will start to leak....

 

[fireman57]

Re: Exhaust Cover Plug won't come out - 93 Evinrude 40hp

I've got my fingers crossed.

 

[marysboats]

Re: Exhaust Cover Plug won't come out - 93 Evinrude 40hp

Try some penetrating oil first, as the plug has started to turn, then use a lock wrench. You may want to call Dad in on this.

 

[Silvertip]

Re: Exhaust Cover Plug won't come out - 93 Evinrude 40hp

The tell tale is essentially a "controlled leak" in the cooling system. It doesn't mattery where you tap into the system. The pressure will be the same regardless. The only way to get a "maximum" reading is to tap into the tell tale port and eliminate the tell tall. Even then, the pressure will only be slightly different since you don't have a closed system like a car. Besides, you are looking for a "change" in pressure as the impeller wears not a specific pressure. Two engines may not develop the same pressure anyway. Install a new impeller and remember what the gauge reads at idle and WOT. Any change from that in the future points to impeller replacement. Another tip to anyone using a hex (allen) wrench on an outboard. Use a quality wrench. Most of the cheap hex wrenches are made of soft material that easily rounds off. Pay a few bucks for a good set. They won't round off and won't break.

 

[Mark42]

Re: Exhaust Cover Plug won't come out - 93 Evinrude 40hp

You are right about the allen wrenches. I have a good set, the problem is the alen screw (in this case a plug) is softer than the good wrenches, and stripped out first. Why they used such a small size is beyond me.<br /><br />Marysboats - "You may want to call Dad in on this." - I don't get it.

 

[marysboats]

Re: Exhaust Cover Plug won't come out - 93 Evinrude 40hp

Being 13 years old, you may lack some mechanical experience.

 

[motorvator]

Re: Exhaust Cover Plug won't come out - 93 Evinrude 40hp

I think it's the boat that's 13 years old.<br />I would drill it out with a 5/16" bit then use an easyout. The plug isn't very thick so don't drill to far in.

 

[marysboats]

Re: Exhaust Cover Plug won't come out - 93 Evinrude 40hp

Excuse me! I misread the post.

 

[Mark42]

Re: Exhaust Cover Plug won't come out - 93 Evinrude 40hp

LOL! Marysboats, I'm almost 48. The motor is 13 years old. The boat is 41.<br /><br />I was scratching my head thinking "But I AM the Dad!"

 

[OBJ]

Re: Exhaust Cover Plug won't come out - 93 Evinrude 40hp

Now that's funny....I don't care who ya' are.....LOLOLOLOLL!!!!!!

 

[Xcusme]

Re: Exhaust Cover Plug won't come out - 93 Evinrude 40hp

Oh God, that's funny !! Thanks, that made my night.

 

[marysboats]

Re: Exhaust Cover Plug won't come out - 93 Evinrude 40hp

That is a laugh! Jeezzz! Where did my head go on that one?

 

[Mark42]

Re: Exhaust Cover Plug won't come out - 93 Evinrude 40hp

Update 5/23/06:<br /><br />I finally got around to finding my extractors and handle and had the darned plug out in 10 seconds. <br /><br />I was surprised at how clean it was inside. <br /><br />Anyway, I put the brass fitting into the plug hole and connected everything up. Hopefully I will get to test it tomorrow.<br /><br />Thanks for all the suggestions. Next time I won't wait because I thought it was all corroded up!

 

[KYHunter2]

Re: Exhaust Cover Plug won't come out - 93 Evinrude 40hp

Thats TOO FUNNY !! You can call me 13 anytime , heck 30 be OK ! Too !<br /><br /> Glad you got the plug out. <br /><br /> KYHunter

 

[surlyjoe]

Re: Exhaust Cover Plug won't come out - 93 Evinrude 40hp

if you cabn get a left handed drill bit and heat it with the torch before drilling it will prolly come out.

 

[Silvertip]

Re: Exhaust Cover Plug won't come out - 93 Evinrude 40hp

In case anyone is interested, the water pressure gauge on my engine (sorry its a 75 Merc) idles at 7 PSI and runs at 15 PSI at 3500 - 4000 RPM. Its T'd into the tell tale.