Well, much like jury duty, I guess my name has finally been drawn. Have my first leaky exhaust skirt for a 9.5 tonight. Runs totally fine at all ranges with the hood off. Put the hood on, and the motor dies out.
I can see water squirting up through the rear starboard side of the skirt, so I’ll be tearing it down in the AM to replace from a parts motor. A couple of questions so I don’t have to do 5 tear down/reassembly’s chasing the source(s):
1. I had to do a full overhaul on the gearcase for this motor and noticed there is no #6 SEAL,Impeller housing and part #7 WASHER, Seal. This is a early 9.5 model that does not have vibration dampeners. Does anyone know if earlier models lacked this seal? If this seal is missing, wouldn’t this allow the area below the exhaust skirt to fill with water and force it’s way up past the skirt, allow exhaust to enter the powerhead area?
2. I will have to take a look at the #78 BOOT,Shift rod.
3. Is it possible that if the #6 seal is missing, then this could essentially negate the ability of the the exhaust skirt from working due to water forcing it’s way past it? The water was basically squirting up past the skirt when I observed it. The form of the exhaust skirt seems like it was designed to basically wedge itself against the lower housing as water/pressure pushes up against it.
4. Has anyone noticed that earlier models which lack the vibration dampeners are more prone to these exhaust leaks, due to everything just getting shaken up so much?
I was wondering if there are any tricks folks have developed if a replacement skirt was not available? I was thinking a large glob of silicone during reassembly, and being REAL careful to make sure it stays air-tight. Silicone is flexible, is good up to 600°, and won’t deteriorate in water.
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