Questions regarding rebuilding 1993 60hp

HybridMX6

Senior Chief Petty Officer
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Oct 22, 2008
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676
Hello. I had tried posting this in my other thread about this motor, but it seems no one is wanting to reply to it, and I need help. So sorry in advance.

My questions so far are this:

It's been since Dec. 1, '08 that I tore this motor down. I needed to buy the parts to rebuild it, so I finally got the money and bought all my parts. My first question is regarding getting the wrist pin retainer clips installed in the pistons. My OMC manual calls for a special tool, but does not show me a picture of it or anything. I can't get the clips in, so I need to know what this tool is, what it looks like, or if there is something I can get from my local auto parts store to use instead, or even if I can make one myself.

My 2nd question is about the o-ring that goes in the shift rod cover on the LU. The original one that was on the engine was literally frozen to the shaft, and I had to cut the cover off. I have a new cover, 3 new o-rings and 3 new seals for that cover (yeah, I planned ahead that I might maul a couple of these). My question is how in the heck do you get this huge o-ring in that cover where it is supposed to go? My manual does not go into detail on this, all it says is "Install new o-ring in cover." I can see a groove for it down in the cover, but the o-ring is so large it literally fills the entire hole for the shift rod if I stuff it in there, and it's not in the groove, that's just squeezing it to get it in the hole. How are you supposed to get this o-ring installed? I was wondering if the brass bushing comes out of the top of the cover, or what? Any help would be appreciated.

So for now, it's sitting in my garage, all parts laid out, pistons, wristpins, needle bearings all assembled except the wrist pin clips, and it's collecting dust, again. If you can help please do, I'd appreciate it.

Thank You
 

bankerjohn

Chief Petty Officer
Joined
Mar 21, 2008
Messages
444
Re: Questions regarding rebuilding 1993 60hp

Don't know if this will help or not, but here's a picture out of the manual for my 1996 9.9 4-stroke motor that the manual says are needed for the removal of the wrist pin retaining rings:

Retainingringpliers.jpg
 

HybridMX6

Senior Chief Petty Officer
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Oct 22, 2008
Messages
676
Re: Questions regarding rebuilding 1993 60hp

Thatnks for the pic. Mine says the same thing, and I got them out with no problems. It's getting them back in that's giving me problems. I had a pair of pliers at home that had a chip in them like this, and they worked great for getting the clips out, but getting them back in has proven to be a little more difficult.
 

HybridMX6

Senior Chief Petty Officer
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Oct 22, 2008
Messages
676
Re: Questions regarding rebuilding 1993 60hp

Can anyone help on this or am I going to have to go pay a shop to install wrist pin clips and this o-ring for me?
 

mikesea

Lieutenant Commander
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Oct 1, 2006
Messages
1,830
Re: Questions regarding rebuilding 1993 60hp

I have installed hundreds by ,starting with one end placed in the slot,,carefully ,using a screwdriver or an awl with strength,go about 2/3 the way around the clip and lever it into place.its spring steel so it will bounce back to shape,I kinda use my thumb on opposite hand to cover the clp should it try and slip out during the procedure.Safty glasses are recommended.Its a procedure that takes a bit of time to perfect,dont guage up the piston and dont start the clip in the slot that enables for removal down the road,it dont help anyway.I have also seemn guys use a small needle nose and push the opposite clip end into the slot.
 

HybridMX6

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Oct 22, 2008
Messages
676
Re: Questions regarding rebuilding 1993 60hp

Thanks for the help mike. I got 1 in, so I have 5 to go, but I noticed while trying to get the other side of the piston done I was starting to scrape up the piston a little. I cleaned the piston up, and stopped doing it that way. I was using needle nose pliers. I think I may try the screwdriver thing and see how that goes.
And on the same subject, but not a question, I noticed when removing the old ones that they were not installed properly. The manual clearly states to have the opening of the clip on opposite side of the opening in the piston for removal later, but on all 3 of my pistons they opening for the clip and the opening on the piston were aligned almost. I know someone's been in this motor before, so I'm guess it was NOT an OMC mechanic, seeing as how I doubt they would do that.

Now if I can just get this o-ring thing figured out, I'd be set to go for a little bit longer. The wife's unhappy right now b/c this motor and all the pieces are sitting in the garage, in her way, LoL.
 

HybridMX6

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Oct 22, 2008
Messages
676
Re: Questions regarding rebuilding 1993 60hp

Mike, thanks for the screwdriver idea, I got them all put back together last night, and at least put into the cylinders again as well. I haven't had time to get the crank and all also back in, it was late when I did the wrist pin clips, but at least now I can keep moving forward, until I run into my next question.

So, anyone know how to get this o-ring in the shift rod bushing thing that mounts to the lower unit? It's right next to the water pump, and the shift rod goes through it. I know someone on here has had to have replaced that thing at least once.
 

R.Johnson

Rear Admiral
Joined
Sep 24, 2003
Messages
4,446
Re: Questions regarding rebuilding 1993 60hp

The main question on your engine is, what caused the engine to fail in the first place. You must determine this, or it will happen again. Most certainly clean the carbs', and install new kits'. On the shift rod o-ring, you simply stuff it back into place, folding in half to start. Put a close fitting drill bit into the hole, and just below the groove. Keep pushing the o-ring down into the groove by working around with a small flat nosed punch. Kind of the reverse of stretching a gnat's butt over a rain barrel. Does'nt seem possible.
 

HybridMX6

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Oct 22, 2008
Messages
676
Re: Questions regarding rebuilding 1993 60hp

I know what happened to it, but I didn't do it. Ibought it this way for a few hundred bucks. More than I should have paid for it, but it was supposedly just a bad cylinder. Water pump was trashed, midsection was full of dirt, carb jets were all messed up from someone trying to remove them before and failing to do so. I've since replaced the entire water pump, cleaned all 3 carbs and installed new OMC carb kits in each, am replacing all fuel lines, VRO was removed before I ever got it, so now it's just a matter of getting this thing back together. I'm hoping to have some time to do so this weekend, but fishing sure is sounding like a lot more fun. Weather's supposed to be ok, but they change that every day, so who really knows?
Thanks for the insight on the o-ring, I guess when I get bored off my *ss I'll sit down and try to get it in there.
 

HybridMX6

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Oct 22, 2008
Messages
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Re: Questions regarding rebuilding 1993 60hp

Ok, well, ran into another problem. I noticed this when taking it apart, but forgot about it. On the intake manifold, I can't get 2 out of the 3 leaf plate assemblies off. The first one came right off, but the other two someone has buggered the threads a bit, and I made it a lot worse. I tried my impact driver, but that made it worse too since it seems it's darn near impossible to hold onto this thing and do that at the same time. I made the threads so bad I decided it would be best to use an easy-out, which hasn't helped me at all yet. Got one hole started with a smaller size, moved on to the next screw, and the easy out snapped. It came right out, but didn't do much as far as getting the hole started.
Anyone else have any other suggestions for the other one I can't get out? The head is gettin pretty bad and the screwdriver slots are all messed up. I just don't know what else to do with it now, and I need to know soon.

Sorry so many questions, but the manual also says to use OMC gel-seal between the crank case halves, is there something else I can use, permatex or something, so I don't have to go back to the dealer for this item?
 

HybridMX6

Senior Chief Petty Officer
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Oct 22, 2008
Messages
676
Re: Questions regarding rebuilding 1993 60hp

Anybody have any suggestions on this last part about the intake?
 
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