Thanks guys for all your help this is an update of what I found and have done.
I put the new rubber grommet on the folding leg part and the new part did not fit around the 1/4 inch copper pipe snugly I think they may have sent the wrong part so I still had to use a small piece of fuel hose to get it to seal like it should. I did this step first to make sure it was sealing while I had the exhaust plate off the motor I used a small piece of grocery plastic bag at the top hole where water enters under the exhaust plate to plug it up and make sure no leakage while I used a small piece of hose with the bottom foot off to blow air and make sure no leakage occurred where the lower leg folds together. I can make up some extras for the owner.
I used a small drill bit to clean the horizontal top tube but like Fleetwin said you can’t go all the way across because they factory put in that water deflector to make the water go down then back up. I managed to clean the small hole on the top cylinder about 1 oclock and the bottom cylinder hole about 4 oclock with metal wire but the water still would not flow sufficiently once I starter motor. Some water would come out the blubber holes but not much. The motor would get warm/hot very quickly like 1.5 minutes so I did not run it long since it had new head gasket and new exhaust plate gasket.
It is possible like Fleetwin said I could pull those small oval caps and see if their is restriction but I did manage to insert the small wire into both and I dont think they are restricted but it could be where the power head bolts down. The owner did not know the history on this motor the impeller was very old I replaced and would kind of tell me the base gasket would be correct but could have some restriction from mud daubers or something. I did see some water coming through the blubber holes so it most likely would not be the wrong base gasket but anything is possible at this point. I could blow a small amount of air through the engine with the small piece of fuel hose connected the copper pipe with lower foot off and exhaust plate installed and the cylinder head installed it just felt slightly restricted still.
When I started motor in the tank I saw a small amount of water blowing out the top of exhaust plate where I didn’t have it quit tight enough so I knew it was getting the water pressure to the power head.
Please don’t blast me for this mod but I have pulled my hair out with this motor and he is at his limit on just what parts have cost I am not charging him labor. He purchased a 4.5hp 1987 Evinrude I went through and loves it and uses it to get back and forth to sailboat. It has the factory tale tail and this motor is for back-up to that motor.
I decided to do something I could undo with a little JB weld and a small screw if I needed to. I drilled a very small hole like 7/64 (similar to the size holes from the factory in the cylinder jackets) into the side of the engine block basically between the cylinders and started the motor. I ran it for like 15 minutes at all speeds checking it with my laser thermometer and the temps stayed perfect like 135-150 depending on where I was aiming the thermometer on the engine block. I am going to insert/squeeze a small piece of tygon fuel hose into the hole I made and run it out the pan to make a tale tail for that engine so he can monitor water flow if he uses the motor. Where the water leaves the hole is around 135 degrees so I am hoping the tygon will hold up if not I am going to jb weld a very small nipple or small pipe in the small hole then use the tygon fuel hose to make a tale tail.
I think with the way the motor folds together the tale tail would be good to make sure water flow is happening when he starts the motor. I think I will end up pulling the power head once I talk to the owner and look for a restriction on the bottom of engine possible mud daubers I can also pull the head and put air through from the bottom of power head to see if it is restricted I could even soak it with CLR or something.
Thanks,
Joe
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