Tstat tip needed

[pieman22]

I have a 1992 115 HP V4 and I need to replace the Tstats. Wow what a hassle to get to the bolts! Any tips in making this task a little easier would be greatly appreciated.

 

[boobie]

Re: Tstat tip needed

Use 1/4" drive tools. You may also have to drill some holes in the back lower cowl to get at the bolts but you can get some rubber plugs at any parts house to plug them. If this mtr has been in salt water a mapp gas torch would also be a good idea.

 

[RZR2007]

Re: Tstat tip needed

Use 1/4" drive tools. You may also have to drill some holes in the back lower cowl to get at the bolts but you can get some rubber plugs at any parts house to plug them. If this mtr has been in salt water a mapp gas torch would also be a good idea.

This is excellent advice, I've machined a pocket in a few of these older motors around here, then machined a piece of UHMW to fill the void, that is held on by the cowling.

 

[boobie]

Re: Tstat tip needed

There was a thread on here a while back where the guy cut out the lower part of the cowl and then put it back in with alum strips for backing and pop riveted it back together. He posted picts and it looked pretty good.

 

[RZR2007]

Re: Tstat tip needed

Sure makes things ALOT easier to get too! I'll have to find those pics. How did he fill in the cut line?

 

[DJ]

Re: Tstat tip needed

If you drop the shroud around the mid section, that allows you to drop the lower cowl a few inches.

 

[pieman22]

Re: Tstat tip needed

great tips!! thank you a ton guys.

 

[DargelJohn]

Re: Tstat tip needed

One more method...I took an old pair of water muffs, cut off the loops, rounded off the ends and slipped pieces of rubber hose over the forks. Stick the forks down in the pan and use leverage against the T stat housing. This gives you enough spring compression to start that middle bolt.

 

[wayneo99]

Re: Tstat tip needed

when i did mine this spring the mechanic/dealer gave me upgraded bolts that use a 3/8 head instead of the 7/16 which makes it easier to use a1/4 universal socket and push in the housing as you begin to catch the bolts.