91 115 Evinrude water pump/Thermostats

[hunt-fish.com]

Anyone know any tipstricks/ for changing the impeller and thermostats on this motor? It's been sitting for a while and I ran it on the muffs yesterday. The heat sensor went off and the heads were hot to the touch. So was the pee stream. One curious note, when I shut engine off water continued to pee. It was like the water from the muffs was running up throught the engine and out the pee tube without the engine running. I've never seen it doing this before. It continued after what one would consider normal drain off.

TIA

 

[Walker]

Re: 91 115 Evinrude water pump/Thermostats

The only way for water to continue to come out the pee hole is your impellor is in terrible shape.

 

[hunt-fish.com]

Re: 91 115 Evinrude water pump/Thermostats

That's what I thought. I've never seen it do that before. The motor has been sitting for over a year and I suspected the impeller dried out and then came apart when I was running it on the muffs.

I've never done an impeller before and my OMC shop manual doesn't have good detail on how to remove the lower unit and install the kit. The shift lever looks like there is a pin that turns part of it loose but, I can't see how the top assembly fits through the hole to take it down.

Thanks,
John

 

[hunt-fish.com]

Re: 91 115 Evinrude water pump/Thermostats

I saw on a another post something about back flushing the motor to get the crud out of the water system when replacing the impeller. Anyone know how/where to hook up to do this? Were they just meaning running it on the muffs?

TIA
John

 

[OBJ]

Re: 91 115 Evinrude water pump/Thermostats

Look at the starboard side in the engine pan. There's a hitch pin in the shift lever shaft that pulls out. Once out, push the shift lever shaft towards the port side. This releases the shift rod. Disconnecting the shfit cable helps.

Don't know of any way to back flush this engine. Make sure when you get the lower unit off that you get all the impeller if it's in pieces.

 

[hunt-fish.com]

Re: 91 115 Evinrude water pump/Thermostats

I see the pin on the starboard side but, it looks like it goes through a 1/4 " rod horizontally from the shift lever over to where the shaft goes down to the lower unit. It looks like there is a small pin and the point where the lower unit shaft joins this bigger horizontal shaft. The hole for the lower unit shaft is too small for the hole assembly to go through.

Also, I don't see any easy way to get to the lower unit shaft itself. Pretty tight space. Am I missing something?

Does the themostat cover come off easily without removing the lower housing? Looks like another tight fit.

If the thermostats were stuck closed, do they work the same as a car thermostat? The water would remain stuck in the engine and the impellar would just push the water out the telltale?


Thanks,
John

 

[Sebrof]

Re: 91 115 Evinrude water pump/Thermostats

I know that in my 1991 Johnson 115, I had to take off the lower carb to get at the shift linkage disconnect, I tried every way I could think of to do it without involving the carbs but in the end it was the only way.
Another trick someone here told me about was when you reassemble the Thermostat housing , wrap it all togeather with rubber bands and that was a great tip to help putting it back togeather. Good luck

 

[limacina]

Re: 91 115 Evinrude water pump/Thermostats

Maybe you should try a Seloc Manual for the procedure, there a couple expensive gottchas you want to avoid. I have twin 97 115 Johnsons, I assume the years are simular?
Why not deal with the waterpumps for now, deal with the thermostats if you still have a problem.
You do split the upper cowling and remove a pin held in place with a cotter pin to get out the shift rod. I didn't have to removee the lower carb. Buy some fine needle nose pliers and try not to destroy the cotter pin.
The drive shaft slips into its hole, not retained inside the pwrhead.
Remove the shift lever, do not shift the top or bottom while it's out, convienent for reassembly.
Remove all of the bolts holding the lower unit up and lower it down. Theres little slits in the gap just above the bolts to carefully pry it with a screwdriver. You can break the alum housing if your not careful!
once inside the pump, I read and understood the procedure for removing the old impeller, but found it much easier to split it with a coal chisel. The center of the impeller is a brass sleeve.
My biggest piece of advice would be to remove your prop and grease the splines on that and your drive shaft before reassembly. When I was in jr high school, my dad would buy junk motors with the drive shaft stuck in the pwr head or the prop stuck on it and have me go at it with heat and cutting tools to free up any parts we could sell. you don't want your motor in this position!!

 

[limacina]

Re: 91 115 Evinrude water pump/Thermostats

Replace all of the gaskets, Easier to reassemble with new and you can be more confident in your work.
I used a good quality automotive waterpump gasket maker sealent in plce of the OMC adhesive and sealing compound and a good wheel bearing grease for the grease. I used Aqualube for greasing the splines and any exposed areas. The stuff is like bubble gum!

 

[hunt-fish.com]

Re: 91 115 Evinrude water pump/Thermostats

I've got the Kit and am reviewing the procedure in the OMC manual and the Seloc Manual. I like the OMC manual much better. Neither do a good job of explaining how the shift rod and shift rod link disassemble and re-assemble (no pictures). That's such a tight space. The shift rod appears to have a small hole in the tip that has a pin of some sort. When I pull the cotter pin on the shift rod link and push it to the port side what mechanism releases the shift rod? The manual says put it in reverse to make it easier. It moves the shift rod down.

Also, the re-installation procedure says in one of the final steps to replace the shift rod seal. The OMC manual has a photo with needle nose pliers. I don't know if this is just to model the guys hands 8) or what because I don't see how that seal goes back in.

Thanks,
John

 

[hunt-fish.com]

Re: 91 115 Evinrude water pump/Thermostats

I see how it works. The shift link is in 2 pieces. Just like OBJ said, It releases the shift rod when you pull the pin and push to the port side. d The small pin in the top of the shift rod follows the shift link and releases it.

On to the next steps.8)

Thanks,
John

 

[hunt-fish.com]

Re: 91 115 Evinrude water pump/Thermostats

OK, I took it all apart, put the new kit in, put the lower unit back on the motor. Re-attached the shift rod. Put the plug wires back on. Hooked up the battery and now she won't turn over. :'( The battery is hot, the cables are tight. The tilt & trim goes up and down. I turn the key with the shifter in neutral, nothing. I've tried shifting into FWD and REV, back to neutral, turn the key, nothing. Is there a sensor or something?

Turns out the last mechanic, Prior owner's freind, left off one of the bolts under the trim tab, not the one that goes to the Anode. It is screw "E" in the manual. I'm going to have to try and find what size that is. Also, he didn't install the water tube grommet. When I use to put the muffs on it water went everywhere. Now it does not. 8) Water comes out just like my '90 115 Johnson.

Any ideas why she won't turn over?


Thanks,
John

 

[Walker]

Re: 91 115 Evinrude water pump/Thermostats

Check the fuse in the wiring loom of the motor.

 

[hunt-fish.com]

Re: 91 115 Evinrude water pump/Thermostats

OK, Checked the fuse, it's good. Opened an ice cold Warsteiner Premium Dunkel (Dark German Beer) 8). She cranked up. Don't know why??? Now there is no water coming out of the telltale. :'( I made sure the key was correct on the drive shaft and the impeller was turned correctly. Did everything by the book. Is it time to take the lower unit back off again and re-check? If the thermostats were stuck closed would this also make no water come out of the telltale? Hmmm ......

Thanks,
John

 

[hunt-fish.com]

Re: 91 115 Evinrude water pump/Thermostats

I checked the telltale tube and it's clear. Blew air through it. I think the impeller is working since water comes out the other holes in the lower unit when the motor is running and does not when it is off. I'm going to drop it back down and check the water intake tube alignment to see if that is the problem.

Question: Is it better to remove the lower unit with it fully tilted up, slightly tilted or straight down? This is on a big pontoon boat so I have plenty of heighth below the skeg.

Thanks,
John

 

[hunt-fish.com]

Re: 91 115 Evinrude water pump/Thermostats

OK, Took it down and the water intake grommet was sideways in the impeller housing thus, blocking the water flow. Fixed that, the telltale is flowing strong. New question so, I'm going to post new. Runs fine for several minutes then the over-temp horn goes off.

John