225 Excell 2 stroke, 1998, overheat saga

[electric sailor]

New owner. Thanks to this forum, I learned how to start the engine (prime till hard (the squeeze bulb) a little throttle, full choke). By the time I learned that, I had overheated the water pump. The original pump housing was white, and partially melted, such that the stainless steel cup had rotated slightly in the housing. The new housing was black, but looked identical, until I discovered the stainless steel cup would not go all the way in. One of the two small tabs on the top of the cup was in a different location. Drilled a hole in the new housing for the tab. Reassembled. Finally got the boat out on the water last week, YAH! Tried to flush the motor when I got home; no stream from the pee hole. I did stir up some mud on the grass flats; did I ruin the impeller (again)? The PO (previous owner) said the pee hole did not stream unless the motor was in the water, but it did immediately after my repair.

 

[99yam40]

my guess is you have the wrong housing.
drilling hole is not the proper way to make it work

 

[electric sailor]

I purchased a new "earmuff", the largest, strongest Wall Mart has. Didn't make any difference. I took it apart and examined all the water pump components. Everything looked fine. I put the muffs on the lower unit while it was removed, and the water just barely came up into the pump inlet. Put everything back together, still not pee out the hole. Took it to the boat ramp and immersed the motor, started, and plenty of flow out the pee hole. Have used the motor for about two hours since, no problem, but cannot flush using the muffs. The new pump housing was different only in that one small detent and the material. The "hole" i drilled did not go all the way through, just deep enough for the new positioned pin/detent. The old stainless cup had two detents as well, just one of them was in a different location.