I/O (Sterndrive) Conversion to Outboards

[Lou C]

I can just imagine the conversations of people putting these together in Fond-Du-Lac, laughing to themselves at the poor guys who actually have to work on them....
The only I/O boat I'll ever have are the older, simpler kind, with wide open engine compartments, carb fuel systems, etc. I look at that and as nice as they work (when new) it makes my brain hurt lol. Changing a starter? A steering actuator? The engines are getting pulled then. In fact I convinced my brother to trade his 2020 Chapparal with the Merc 4.5 for a brand new Chap with a Yamaha 4 stroke outboard...before the headaches started. One bout of mild overheating due to marine growth in the water intakes (that I told him would happen unless they are rodded out) was enough for him.
You're on the right track Ted and you'll wind up with a unique boat, probably the ultimate for your boating area....as for me being the skinflint that I am, and admirer of simplicity, I'll stick with this.....

 

[tpenfield]

It took a while, but I got the lower bolt for the steering actuator loosened. Then I could remove the water intake hose and expose the rear mounting bolts.

.
They came out fairly easily . . .

.
I believe these are stainless bolts . . .

.
So, I just need to disconnect the fuel line and the starboard engine should be ready to lift.

 

[tpenfield]

Hi @Lou C - Yes, it has been you and I against the salt water Gods, so it seems. I will say that there is a lot of engineering that goes into these I/O (sterndrive) systems. Amazing that it has worked for so many years.

I'll be happy to send these engines to someone needing a twin engine re-power.

 

[Lou C]

Ted your patience is an inspiration!

 

[alldodge]

A bit late, but did you think about removing the oil cooler to gain access to bolts?

 

[tpenfield]

I did for a moment, but the steering actuator was more directly over the bolts.

 

[tpenfield]

A bit rainy today, so not as much work done. I did go to Harbor Freight to get a tool for the steering actuator.
.

.
I was able to get the 1" socket on the lower pinch bolt from above with this wrench. Much easier than yesterday's work.
.
I should be ready to pull the engines tomorrow . . . Here is where things stand as far as all the stuff to disconnect. I'm saving the fuel lines for last.
.

.
My learning curve kicked in and I was able to do stuff on the port engine in a fraction of the time. Just don't want to make a habit of pulling engines . . .

 

[tpenfield]

! down, 1 to go . . .

I had to update my chart. As I was lifting the first engine, the starboard side did not want to go. So I put the engine back down and discovered that the alternator feed and Mercathode power needed to be disconnected.
.

.
Then the engine came up as expected . . .

.

.

.

.
The engine looks OK. I'll want to re-assemble some of the stuff that needed to be removed during the process, and clean the engines up a bit.

Now onto the second engine . . .

 

[Lou C]

Great work Ted.

 

[aspeck]

My wife is pretty understanding and easy going, but if I started a project like this in our driveway I don't think it would go over too well!

 

[tpenfield]

Engine #2 is done and safely on the ground.
.

.

.

.

.
Big milestone for this project . . . .Looks like I'll be cleaning up the engine bay tomorrow and then some.

 

[redneck joe]

My wife is pretty understanding and easy going, but if I started a project like this in our driveway I don't think it would go over too well!

My wife hasn't had the garage in 6 plus years. She must love me..

 

[Lou C]

Wow great progress
I think if I tried that, I'd be getting what we used to call in Brooklyn
"La Faccia Brutta" from my better half, lol...

 

[tpenfield]

I'm doing this work at the summer house, so not a big deal as to the use of the driveway, garage, etc. Just as long as I'm done by summer time

 

[tpenfield]

For anyone referencing this thread for engine pull, here is my final check list, as I added a few things on the fly during the 'pull'.

 

[redneck joe]

...... as long as I'm done by summer time

Oh snap, a deadline. Yer screwed....