Re: "Newer" 25/35hp OMC compatibilities

[johnyrude200]

The issue I have here, is that a couple of the exhaust cover screws broke off in the motor. I tried drilling them out, but 1 of them the tap broke off in. Lucky me. It seems that the most important ones are in the middle of the cover, as this is where the exhaust pulses would get through to affect water flow.

So I ended up fabricating a new plate from 1/16th aluminum (same thickness as the original baffle). I widened out the inlet hole of water supplying water to the cylinder water jacket. I also used some crankcase sealant on the metal wall that if the baffle separates away from, exhaust gases would push the water back down the water inlet at the base of the powerhead. I had to beef this up, beyond the typical OMC gasket sealant, because one of the missing screws is a middle one on the cover. So I don’t want to chance anything more than I have to.

I’m letting it sit overnight and will report back. I’m hopeful that this is strong enough to prevent issues anytime soon. I’ll hold onto the old baffles if necessary.

I think this motor was a mixed use (fresh/salt) motor. Spent a lot of time on this one, so the only 2 other things I can think of which would affect the cooling system is that rubber grommet under the powerhead or I can double check the o-ring in the impeller housing to see if it needs replacing. That is…beyond the typical things (which I’ve already gone through).

Running out of time with this one — only a couple of weeks left before it is WAY too cold to be out in a boat!