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Clooling problem

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kevinc1820

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Hi all i am having an issue with intermittent water coming out of the tell-tale. I have changed the impeller and blown air through the tell-tale with lots of air coming from the intake. The water pump seems in good condition but I will change it to see. Can anyone think of another reason its not working.
 
racerone said:
And what motor do you speak about??
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Sorry its a 1996 johnson 9.9.9hp with pull cord. I changed the thermostat today still the same. I tried putting an air compressor through the tell-tale again and noticed air coming from this point where the gear linkage comed through. Any help would be great
 

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Droid said:
What brand impeller did you install?
Do you have the vanes facing the correct direction?
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It was an aftermarket impeller that looked the same as the original one. The old one didn't look that bad either to be fair. I rotated the drive shaft clockwise when I mounted the water pump.
 
I have done some further checks. I dropped the lower unit again and placed it in a tub of water. I then turned the drive shaft and there was plenty of water coming from the water pump. I then attached a hose to the copper inlet water pipe the water came through the tell-tale but there was a lot of water coming from further up on the copper pipe. I have read that there can be problems with the rubber Grommet at the top of the pipe. I beleive I will have to remove the powerhead to check. Would I be correct in thinking that and how much work is involved.
 
Water returns to the lake.----So yes you will see a lots of water coming down.----Are you testing it in the lake ?----Water in a test bucket must be 6" above the impeller.
 
Since you mentioned the copper tube, it must be a long shaft. Note on the picture there is a grommet with a male end (#68) that is on the top of the tube sealing against the bottom of the next housing. If the tube pulled downward when you removed the lower unit, the grommet was displaced off the end of the tube and is no longer sealing.

Remove the lower unit WITH the extension housing as 1 piece & reinstall the grommet onto the tube then reassemble the extension housing/lower unit as an assembly.
 

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Short / long / extra long all use a copper tube.----Depends on whether extension was factory installed or with a kit as to what is actually there..
 
Droid said:
. If the tube pulled downward when you removed the lower unit, the grommet was displaced off the end of the tube and is no longer sealing.
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I’ve had several motors where the copper tube came off with the leg.
Just pull the tube out of the water pump, & stuff it back up into upper grommet. (You’ll have to twist it to orientate to the water pump upon assembly).
That grommet has a flange, which prevents the grommet from being pulled down. The powerhead prevents it from being pushed up. (The powerhead has to be removed to replace it), it has to go in from above, the flange prevents it from being able to be pulled downwards.
I recently fixed a 9.9 where that grommet was swelled up, blocking water flow. Yes, powerhead must be removed, & you need a new gasket that goes on bottom of powerhead.
 
I just did a 2000 10hp 4 stroke (20") & the tube pulled out enough for the grommet to become loose between & not go back on.
I simply unbolted the assembly at the upper edge of the 5" extension (bolts #64), slipped the nipple back onto the top of tube & reassembled.
I also spun the driveshaft with a drill & got all sorts of water flow.
Here is the parts diagram for that motor. I see no difference other than #67 instead of #68. What does he have to loose other that a few minutes of time.

Maybe you can get the tube to slip back in, IDK. I simply unbolted at the upper flange. Same amount of work, still need to pull the clip from the shift lever & remove 6 bolts. The copper tube is straight, no curves.
 

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racerone said:
Water returns to the lake.----So yes you will see a lots of water coming down.----Are you testing it in the lake ?----Water in a test bucket must be 6" above the impeller.
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Hi. I had the test bucket filled all the way up to thr top of the lower unit. Can you think of anything else to try before taking off the power head
 
kevinc1820 said:
...... I have read that there can be problems with the rubber Grommet at the top of the pipe. I believe I will have to remove the powerhead to check. Would I be correct in thinking that and how much work is involved.
Click to expand...
This was a known issue on the 9.9/15 engines. I had a 1979 9.9 and chased cooling problems until I replaced the water tube grommet then all was well. It's not a bad job to remove the powerhead and you can get all the work done on a Saturday. You'll need Part # 0330426 Water Tube Grommet and Part #0325721 Power Head to Exhaust Housing Gasket for the job.
 
I ran into an overheating issue yesterday. Have a 1978 Johnson 4hp. Went through all the vernaculars, new fuel line to fuel pump, new fuel pump, newfuel line to carb. Rebuilt the carb, 90 pounds of compression both cylinders, super white spark on the plugs. Dropped the lower end replaced the water pump, inspected the prop and gear assembly it was good, drained the old oil in the lower end after 20 years. And it was still pristine ish for 20 years, and put in new gear oil. I put the lower end back in, and it starts right up smoked alot but I was so happy, surprised, I didn't look to see if she was returning any water. Within 2 - 3 minutes she stopped, very hot. I could still mannually turn the prop after it cooled down, so I don't think it is seized. I failed to check the water pump before installing it back into the lower end.
What should my next step be?
Also how important is the o-ring below the shaft grooves/spline that fits into the powerhead? It didn't have one when I took it apart. Thanks in advance, 300 dollars in and still learning! 😆
 
I took the power head off and I gave it a good clean there was build up of sand and salt all over the place. Under the air cover where the tell-tail connects was really bad. That may have been the cause. I am waiting on the gasket kit coming then i can put it all back together. Is there anything else j should do while the powerhead is off. It's the first time I have worked on an engine and I am enjoying doing it. I just hope I can get it all put back together again.
 
A suitable o-ring would be available at any good hardware store .
I assume it keeps any errant water out .
Which helps with the shaft not seizing too the female output spline .
 
Well I guess I will find out tomorrow morning when I try to pull the shaft out, check the water pump, the return line and put the gasket on. Fingers crossed.
 
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