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  1. W

    Blown head gasket / overheat

    It was a long and confusing road but as a courtesy I'll try to distill this for others: Symptom: motor was overheating sporadically. - went for the obvious stuff first. Checked the thermostats which were both bad. Replaced them. Still overheats. Messed around with IR gun but could not...
  2. W

    Broken head bolt. Evinrude 150 E150EXERV.

    That's about how he did it, in so many words. He drilled until there was only a tiny ring of thread left and the used a tap to clear that out and blow out the pieces. He was a professional welder but around here everyone has a boat and so your likelihood of finding someone who knows what...
  3. W

    Blown head gasket / overheat

    Looks like she's running great now... https://photos.app.goo.gl/wtGXUHakyYUiPC1E7
  4. W

    Blown head gasket / overheat

    Indeed they are hard to find. I put a starboard sensor on the port side and just grounded the black/white wire to the warm up circuit so it's essentially always off. It closes at a pretty low number near 120 I think or lower. After 3 minutes she's warmed up anyway.
  5. W

    Blown head gasket / overheat

    It's premixed. VRO is unplugged (no alarms possible from that). When I get the alarm I can make it stop by unplugging the overheat sensor on the starboard side. I'm buying two new ones. This will be the second set I've purchased. They've been bad out of the box (I used OEM). Same for...
  6. W

    Blown head gasket / overheat

    Alarm goes off, drop off a plane to idle, remove cowl and pull starboard sensor lead out, horn goes out. VRO has been unplugged (no warnnings) , and gas pre-mixed 50:1.
  7. W

    Blown head gasket / overheat

    I'll address your message in each point: The overheat alarm is confirmed by unplugging it while the horn is going off. Plug it back in the horn returns. It will work like this for about 1 minute at idle at which point the horn will turn off and you're free to go on your way. The boat is a...
  8. W

    Blown head gasket / overheat

    I have done similar. I had my wife drive while I hung over the transom with a IR gun. I only spot tested but temps were all good on the heads. Then a continuous beep, we drop to idle and immediately shoot with the gun and we're running normal temp while the horn was going off. After about a...
  9. W

    Blown head gasket / overheat

    I have one more question. When I repaired a frayed wire leading to the overheat sensor the wire was shortened a bit so it is just able to plug in. When installed the wire runs very close and possibly parallel to a spark plug wire. Is it possible for induction from the wire at high speed trips...
  10. W

    Blown head gasket / overheat

    Sean, this description you've given is helpful. It would seem several of us including me think there's some sort of frayed wire or short.
  11. W

    Blown head gasket / overheat

    There's no gunk in the heads although there's no way to verify this. Unlike earlier models, the heads are self contained -- one inlet and one outlet. I checked to be sure they weren't warped and I cleaned them up well but I didn't true them to a high degree of precision.
  12. W

    Blown head gasket / overheat

    Raw water pump is fine. I have a gauge and it reads maybe 5PSI at idle and 25-28PSI @ 4000RPM, 30 PSI wide open. Pee stream is fine. I'm looking hard at the temp switch and here's why: I took the boat out today with a driver so I could take readings underway. I used a temp gun to take...
  13. W

    Blown head gasket / overheat

    I'll note the passage from my original post where I replaced the "raw water pump" otherwise known as a "water pump" but I deal in bigger boats too where there is a distinction. Here's the data in case anyone is interested. Model : E150EXERV '94 Parts replaced or rebuilt and verified working...
  14. W

    Blown head gasket / overheat

    I'm getting overheat horns in the following way: Let idle for 10 minutes -- temp readings within spec Run 4K RPM for 15 minutes -- overheat warning horn. Stop the boat, turn off the motor for about 1-2 minutes, restart and go on my way. 4K RPM for 5 more minutes, same overheat. Start...
  15. W

    Broken head bolt. Evinrude 150 E150EXERV.

    I think you might be referring to one of the commenters but I'll chime in here: I didn't drill anything, but the shop did, by hand. Their repair was successful in the end and cost me next to nothing.
  16. W

    Broken head bolt. Evinrude 150 E150EXERV.

    These guys charged me $50. They do about anything. It took them a while since they did it between "real" jobs.
  17. W

    Broken head bolt. Evinrude 150 E150EXERV.

    That's pretty much what the welders did. They drilled the bolt until only a thin layer remained then removed it with the tap. Anyway they got it out and I was able to purchase a new head bolt and get it done. It cost me $50 so I cannot complain at all.
  18. W

    Broken head bolt. Evinrude 150 E150EXERV.

    Recap: I took it to a welding shop who said they could get it out. They tried welding a nut onto it etc but it was too brittle and kept breaking. So they drilled, punched, drilled, punched and used several grinding and drilling bits. Finally got through and they decided to run a tap into the...
  19. W

    Cleaning water passages Evinrude E150EXERV

    I did a little research and this head sold on eBay looks identical to mine, right down to the witness marks from the dead end tubes. I'm not going to worry about it. Here's the head I found: https://www.ebay.com/itm/294389380129
  20. W

    Cleaning water passages Evinrude E150EXERV

    The one in your attachment looks like mine. It appears to have the same corrosion marks, but do I see some small passages in there or was the aluminum corroded away to look like a small hole? I've poked them with a center punch and a razor blade and looks like there's no passage that I can...
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