1968 Evinrude Sportwin 9.5HP Water Pump Issues

[Harritwo]

68 evinrude had carb issues. With everyones help, got those sorted out. Water pump impeller was replaced. Tube and Seals were replaced. The tube from the pump going into the power head, is there a seal or simply an O-Ring on it?

On the parts breakdown, http://shop2.evinrude.com/Index.aspx?s1=5thm81k2fv6tjqdm3nsqnc3cm6&catalog_id=0&siteid=1 piece 54 and 55 I am unsure as to what they are and where they should be positioned. The plate inside the housing, piece 79 http://shop2.evinrude.com/Index.aspx?s1=5thm81k2fv6tjqdm3nsqnc3cm6&catalog_id=0&siteid=1 has 3 screws. I assume the tube goes in from the top side and is held in place with the push nut and has an O-ring seal. Then the plate is installed and tightened down. (Of course, the shift boot piece 78 has to go in before the plate piece 79 is installed.

Can anyone confirm or provide more insight as to the proper assembly of this portion?

 

[F_R]

Do you have the powerhead off, or what? What you have written is more or less accurate. The push nut prevents the tube from being pulled out. The tube & push nut assembly lie in a pocket in the top of the exhaust housing. That pocket is kind of funky, with the side cut out. The washer sort of holds it in the pocket so it doesn't slide out of that side cut-out. Then a fat o-ring on top of the washer makes the sealed fitment to the powerhead. The powerhead also has a drilled hole that fits down over the end of the water tube, further helping hold the tube in place. So, with the powerhead off, that whole assembly is sort of iffy. But with the powerhead on, it is pretty secure. Unless the tube is pulled downward, out of the push nut. Then you have a problem.

I realize some people have managed to get a pulled-out water tube back up in place. Frankly, I don't know how they did it. The usual procedure is pull the powerhead. A fearsome job for the average novice.

BTW, that shift rod boot is a real troublemaker. If it rips or tears or leaks, it allows exhaust smoke to pass through. That exhaust then goes up and out through a vent hole at the top of the exhaust housing. Once out of that vent hole, it is under the motor cover hood and is sucked in through the carburetor, and the motor won't run worth a hoot. Moral: Any time you have the boot out, replace it if there is the slightest doubt about its integrity.

 

[Harritwo]

F_R, currently I have the lower unit off. I have not pulled the powerhead. Is it possible to put the tube through the plate with the pushnut on the powerhead side, install the O-ring, then install the shift rod boot, and tighten the plate in place without pulling the power head from the housing?

When I split the lower unit, the water tube came out in my hand. That is what started this issue, and now am trying to decipher the diagrams as to how to re-assemble it correctly.

Do you have any idea as to a source for the shift rod boot since OMC shows it as NLA?

 

[F_R]

I can't say I know the answer to the question about installing it from below. nymarine, in Canada, is making reproduction boots. http://www.nymarine.ca/grommets.htm