9.5 Johnson: Copper Water Tube Troubles

[lsee]

I have a '72 9.5 HP Johnson, and am replacing the water pump. The problem I've run into is that the copper water pipe running up from the pump came out with the lower unit and pump. From what I've read, it should have stayed attached to the motor. <br /><br />How do I reattach this pipe? There is a hole next to the shift rod that it goes through, but clearly it needs to fit into something else about 3 inches above that hole. Any suggestions? I can't believe that I should leave it flapping around in there, and judging from the end of the pipe, something had a pretty good grip on it before I got it out of there. <br /><br />Thanks in advance for the help!

 

[Paul Moir]

Re: 9.5 Johnson: Copper Water Tube Troubles

Welcome to Iboats!<br /><br />Oh no! - I think that's a job and a half to fix. Search this forum for '9.5 water tube' and you'll find some posts with the skinny on fixing them when they come loose. You'll want a new water tube grommet, among other things...

 

[lsee]

Re: 9.5 Johnson: Copper Water Tube Troubles

Thanks for the quick reply! The earlier discussion was helpful, if not discouraging. It does raise one question though:<br /><br />To reattach the water tube, do I need to remove the power head, or will I be able to get away with seperating the housing on this motor? <br /><br />Also, the grommet I need is the one located on the power head, no? Keep in mind this is the end of the tube I currently cannot see.<br /><br />Thanks!

 

[Paul Moir]

Re: 9.5 Johnson: Copper Water Tube Troubles

Yes the grommet is at the base of the powerhead - or more precisely the top of the exhaust housing. It seals the water tube to the powerhead. I've never had to do this on a 9.5, so I'm just going off the exploded views at IShopMarine. But in one of those old posts Chinewalker said he had to remove the powerhead (and therefore the steering and housing) to get it back in. You can trust the advice he give completely.<br />Still, if it were me I'd give a shot at re-inserting it employing a flashlight, mirrors or whatever else might make it easier to see - if that is even possible. If you do end up pulling the whole thing apart to do it, I understand that the exhuast 'doughnut' seal that seals the leg is often a source of problems - so examine or replace it outright.<br />Be very careful with the rubber isolators - the studs on them are aluminum and break easily.<br /><br />There's a couple people who frequent this forum who know the 9.5s inside out and upside-down. Keep an eye out - I'm sure they won't be long.

 

[lsee]

Re: 9.5 Johnson: Copper Water Tube Troubles

Great Advice. Thanks a lot Paul. <br /><br />There's a plate that this tube slide through that I should be able to remove with 3 screws. Maybe I'll get a better look at where this tube goes then. <br /><br />Hopefully there will be an intact grommet there that it will slide right in. If not, I'll start pulling parts off until I get to it.<br /><br />I did notice that Ishopmarine didn't sell the parts I would need for this. Does anyone know if they are available anymore?<br /><br />Thanks!

 

[P.V.]

Re: 9.5 Johnson: Copper Water Tube Troubles

Well..... Lets cut to the chase... You are screw'd, big time!! lol.. The powerhead must be removed plus all the linkages for the throttle, rubber pads/ lower mounts, side covers, etc.... If you can get that motor apart and back to gether and have no additional parts left over.... You should apply to be a tech at a dealership !!! I trust you have patience and lots of... patience!!

 

[rodbolt]

Re: 9.5 Johnson: Copper Water Tube Troubles

hello<br />I am with P.V.<br /> having done that job many times I wish you lots of luck and no salt water corrosion. many of the mounts are NLA.<br /> I no longer will touch one.

 

[lsee]

Re: 9.5 Johnson: Copper Water Tube Troubles

Wow. That's discouraging. Anyone have a step by step on disassembly of this motor? I'm trying to figure out what to pull off first.<br /><br />It appears to me that I need to split the casing first. I was thinking about trying to get the port side of the casing off, and then pull the powerhead out of the starboard side. Any thoughts? <br /><br />I know you're going to tell me to get the OEM manual. But that's not going to happen on Easter Sunday, and I am going to start this job today. <br /><br />Any and all help is welcomed. I'll let you know how it turns out. Thanks.

 

[Joe Reeves]

Re: 9.5 Johnson: Copper Water Tube Troubles

As Paul states, that tube can be re-installed the same way it came out. However, it does take a lot of patience, a strong flashlight with a concentrated beam (not the flood type), and a good eye.<br /><br />I've replaced a few of them in this manner. The first project being to locate the hole the tube goes in. Good luck.

 

[lsee]

Re: 9.5 Johnson: Copper Water Tube Troubles

Joe,<br /><br />I just discovered the washer that made the scrape marks on the tube. It's on the floor, not on the engine. It appears to me from this, and the marks on the tube, that it is clamped in by some kind of compression fitting to the power head. Am I missing something here? You guys are making it sound like there is a rubber grommet up there. Let me know what to expect.<br /><br />Thanks for all the help.

 

[lsee]

Re: 9.5 Johnson: Copper Water Tube Troubles

For what it's worth, taking it apart isn't all that bad. I never would have found that hole in a million years, now that I know where it is. <br /><br />Now to find the parts, and more importantly get it back together with all the pieces in the right place.<br /><br />Any preventative maintence I should do while I've got the powerhead out? Thanks for all the help.

 

[P.V.]

Re: 9.5 Johnson: Copper Water Tube Troubles

The "washer" is a crimp'd fit on the top of the tube. It's what holds the tube up at the top of the exhust/base of the powerhead. The powerhead must be removed from the exhust housing to relocate. Also, I'd really check that flat plate up inside the exhust with the three screws. There is a rubber bellows that gets a ho0le in it, (it allows the shift shaft to go up and down while sealing out the exhust so that it doesn't come back into the carb when running) anyway, make sure that the bellows is not rippp'd or you'lll be doing the job twice. BTW, good luck in getting the three screws out also. Let us know if you get it all apart and back together, you'll probably have killed the dog, driven the kids to run away and will be up for divorse procedures soon!!

 

[P.V.]

Re: 9.5 Johnson: Copper Water Tube Troubles

Oh, additionally, by "ripping" out the water tube, you didn't happen to stretch/lengthen the tube did you?? Do you know the correct configuration of it do you??(the tube can't be too short nor too long and it must clear the rotating driveshaft after it's put back in place! BTW, I would tell a paying customer that I wouldn't even attempt to repair this motor unless he gave me the "big bucks" up front!!!! To do the repair yourself may be OK, but I'd probably never do it for a paying customer!! No matter how much he wanted!! It would be a job most would not care to fight over with the customer. Some/most of those little parts may in fact be N.L.A.!

 

[lsee]

Re: 9.5 Johnson: Copper Water Tube Troubles

I've got her all in pieces right now, and pretty happy about it. Only one broken cast aluminum piece (part of the shift mechanism up at the top). <br /><br />Got the three screws out, didn't help me much though. The bellows looks good, but even now it's difficult to get to. Is a small hole there really the end of the world (dare I ask)?<br /><br />The 'washer". It's gotta be outside the grommet (which looks more like an O ring). I don't see what holds it up though. Still trying to figure that connection out for all the corrosion there. Currently flushing the waterjacket from that hole. Seems to be doing better. Hoping the replacement parts will give me a better idea of how that connection works.<br /><br />I'm starting to think these engines weren't designed for use in salt water....<br /><br />Anyway, thanks again. This is a really usefull board. And if anyone can think of anything else I should be replacing at this point, let me know. Planning to buy parts tomorrow, and I really don't want to do this again.

 

[lsee]

Re: 9.5 Johnson: Copper Water Tube Troubles

ah, yes, the "ripping" of the tube. I have no doubt that it is not exactly the way it was, but it's what I have to work with, as I am pretty sure that it is one of the NLA parts....<br /><br />I'll find a way to make it fit, or fabricate a new one. That's the least of my concerns right now. I'm just hoping to remember where everything goes.....<br /><br />And I agree, if it were my line of work, you couldn't pay me enough to do this. But seeing as it's my engine, and not worth paying someone else to do it, I figure it's worth a shot. So far I'm still entertained and not cursing to myself. And if I can't get her back together, I'll sell parts on ebay. At least I can return the water pump that started this whole mess.<br /><br />Thanks.

 

[P.V.]

Re: 9.5 Johnson: Copper Water Tube Troubles

Getting it apart is possibly the ez part, it's getting it back together corretly that will be the sh*%s!! We're not laughing at you.... well, maybe we are!! Good luck!

 

[lsee]

Re: 9.5 Johnson: Copper Water Tube Troubles

OK, so I can find all my parts except for the cast aluminum piece that broke on disassembly. Turns out it's NLA!!!!!<br /><br />Anyone got the piece of the shifter linkage that the bolt with the extra shaft out the top of the hex head that keeps you from opening the throttle in neutral goes into. That is to say, there is that bolt with the funny lookin head on it. It screws into the piece that got broken. PN: 309871<br /><br />Surely somebody's got an old outboard graveyard with some parts engines? Where do you guys typically find stuff like this?

 

[Paul Moir]

Re: 9.5 Johnson: Copper Water Tube Troubles

Places like Twin City Outboards, or Marine Parts Outlet, or I have an outboard graveyard not far away. Likely you do too. If it isn't obvious in the Yellow Pages, ask your friendliest dealer where old dead outboards go.<br />I'm glad to hear it came apart easily enough for you. That's not normally the case in my neck of the woods. <br />When you reassemble, put sealant on all the screw threads. That way if you ever disassemble it again, it'll come apart much easier.

 

[wayne h]

Re: 9.5 Johnson: Copper Water Tube Troubles

i might be able to help u with that u need email me with what u need i have pleanty of parts and am willing to help out a fellow boater <br /><br /><br />wheinlei@tampabay.rr.com

 

[rwcreigh1]

Re: 9.5 Johnson: Copper Water Tube Troubles

i just did this job.just use a flashlight tilt the engine and look in the exaust housing and you will see the hole just line it up insert it.then just guide it as you push the unit up.good luck