1974 Evinrude 9.9 Exhaust housing

[PW2]

I got this motor from someone after it overheated,and I had to resurface the head. I also took aff the lower unit to replace the impeller and check it out. So far, so good, but I checked the water flow thru the block by hooking it up to a garden hose, and I found a huge water leak in the exhaust cover plate. Not sure exactly if it is just a gasket leak or if the cover plate is broken or split, but here is the problem. I can't get a wrench on the bottom right hand bolt under the motor mount on this thing. I'm really hoping I don't have to remove the powerhead just to remove this cover plate, but I'm not sure I see an alternative. Any ideas on how to fabricate a wrench or something so I don't have to remove the whole powerhead?

 

[PW2]

Re: 1974 Evinrude 9.9 Exhaust housing

Bump--I'm really hoping someone will come up with a way I can remove that cover without having to remove the powerhead to do it!

 

[mikesea]

Re: 1974 Evinrude 9.9 Exhaust housing

been a while,but,if i recall there are some bolts in the pan that if removed will allow the pan to drop enough to get at bolts,likely 3/8 or 7/16.the bolts you are trying to get at are 3/8 again if i recall,you might get a 3/8 flex head socket ,1/4 drive,crastsman has them,not many make 1/4 drive flex,if your lucky thatmight do the trick itself,dont know if its a salt water used motor,but,those bolts are notorious to stick and often break,go slow,one other trick,ive seen people drill a hole through pans and weld them up,epoxy em up,not me,but in a pinch it can work,theres lots of rubber plugs out there that will repair it too

 

[PW2]

Re: 1974 Evinrude 9.9 Exhaust housing

No, it's not a salt water motor. All the other bolts have come out easy, and I have no reason to think this one will be any different

I'll look again tomorrow to see if there is anything that I can drop down to make it accessible. Those are 7/16" head bolts holding that cover on. I've had to buy a 5/16" and a 3/8" flex drive sockets (1/4" drive) for other outboard projects, but I don't think a 7/16" will work in this case.

I've pretty well resigned myself to removing the powerhead. If it is anything like the 6 hp Johnson that I just did that on, it sounds a lot worse than it actually was--hopefully that will be the case this time too-we'll find out tomorrow.

Thanks

 

[PW2]

Re: 1974 Evinrude 9.9 Exhaust housing

Ok, I finally got that exhaust cover off, but there is no way I'm going to get it back on without removing the powerhead. I've got everything ready to remove the powerhead, but there seems to be 4 phillips head screws on the upper lower unit holding the exhaust housing, just below the cowling, and it appears that they have to be removed before the powerhead will come off.

I can't get those screws to budge. I've been beating on it with a hammer and an impact driver to no avail, and before I go the route of getting ever bigger and better hammers, I thought I'd ask someone if they had any better ideas??