Evinrude extension 'kit' and water pump

[Wildman]

Lets start off by saying the Bay MFG kit's directions are less than adequate... and thats putting it lightly. They suck. The other problem I think I am having is there are missing parts (o-rings and seals mostly) in the motor to start with! I have no idea how this thing didnt overheat.

I have never done a water pump on one of these motors and I would appreciate another pair of eyes from some guys who have, to see if I have put it together correctly. Also if anybody has done one of these extension kits, please let me know if something looks out of place.



The large plastic tube over d-shaft has 2 seals, O-ring on top and large seal on bottom
The copper tube fits tight into the OEM waterpump seal, the 2 round plastic pieces have an O-ring between them.
The shift shaft has the extension screwed onto it, and I slid the plastic tube over it and put the extra rubber bushing on top (so seal it to the upper housing I think?) The seal in the alum housing (uses 6 bolts to hold it down) seams good. That long plastic shift tube looks long to me??

Everything I have is out of the 'kit'
Am I missing anything?

[Bigshrimpin]

Wow!!! That's a weird looking setup. The merc one has all machined extension pieces and the little flared copper water tube extension. Nothing like those PVC pieces.

[Wildman]

Yea these have a machined end for the seals to kinda sit on, and the copper tube is the 'water extension' But thats it. The directions are a little less than helpful.

[DonV]

Holy Cow!!! It's ben quite a few years since I worked on an OMC/BRP.....never did an extension kit however that's one wierd setup!! I would have thought if you extended it 5inches everything added would be that long to make it sync up. What's with the long piece of PVC over the shifter shaft. Keep us informed, looks like fun! Oh yeah....it's neatly strange!

[Wildman]

Neatly strange... thats one way to put it.
I think the OEM plastic thing on top of the alum plate just below the red arrow needs to go away, and it will make the plastic tubes close to the same height. The grey plastic tube is over the shifter rod to hold up that rubber doughnut against the body of the motor.

[Old'sCool]

So I just added a Bay ext to my Yam 250 OX66 and it was very different. I was ok with the product and the hardware but the (hope you're listening Bay) instructions and customer service help sucked. I swapped pics with them and never received a response so.......I cant help with the OMC stuff but here's pics. I'm still wondering about the exhaust gasket

[Wildman]

Reel: you have any pictures of the lower all ready to go back in there?
The exhaust gasket meaning the large rubber one around the exhaust stack? My stack wouldn't fit with the stock one, and the new extension came with a little sealant in the groove. I am hoping thats all I need.
Here are the 'instructions' its more like a half asse'd exploded diagram with the parts in the wrong spot.

[thehermit]

I remember doing one on a 115HP years ago...it came with the little PVC stuff. It worked. I think I still have the rig I made to drill the mid section for the driveshaft extension. Crazy holesaw on a rod thingy. I left my extension on for 2 years on a moored boat. When I went to get it off for service it was an absolute bear.....Galvanic Corrosion! Watch those studs through the alumn extension.

[Old'sCool]

These are the only others I took.





The OMC "boot" is what I questioned on mine. I kept the original rubber seal on one side but the other is open. There was no mention of one in the instructions. I'll watch it and if it appears to leak/stain I'll install something.

[Wildman]

Yea I saw those pics. Its crazy how close the Yamis are to the OMC's I left the 'boot' shaped one in there it fits pretty tight to the extension one, with the supplied gaskets. My concern is it will shake loose and crack. Who knows.
Thanks Hermit, I am going to throw it back together and run it on the hose this weekend, see what happens! If all goes well, and the wind dies down a bit Ill have to take it out and burn some fuel!