Merc 90hp 2stroke/ 2004 over heating above 3000rpm....

Danishbrian

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Joined
Jul 23, 2019
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Hi Guys... i need a bit of help on this one....long story short... picked up engine second hand , low hours, and from a dealer, who allegedly had given it a full service......first trip out and engine sounds smooth as anything, until i go above 3k rpm and over heat alarm comes on... so i change thermostat and service poppet valve -- back on the water and same problem, so i have now changed water pump housing, impeller, and the faceplate, so basically a full service, havent had it out yet, but tell-tale is noticeably stronger... so now comes the question: while i had gear-case off, i pushed bore-scope camera up in the water tube to check for debris, and noticed a restriction where tube bolt on to the exhaust plate, as per picture attached.... it looks like the seal is squashed in... i thought about cutting it out with a moified holesaw or should i not bother? is this normal for the seal to restrict the tube?.... thanks for your help....
 

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