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.

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They came out fairly easily . . .

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I believe these are stainless bolts . . .

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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.
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I was able to get the 1" socket on the lower pinch bolt from above with this wrench. Much easier than yesterday's work.
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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.
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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.
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Then the engine came up as expected . . .

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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.