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The skeg is broken. To me all the model 4203’s are the same, whether its the first or last, lol. At any rate, Pals are plentiful so finding a replacement lower unit shouldn’t be hard. Exchange the entire lower unit and you probably won’t have to worry about gears. Those gears are mild steel and once they get heavily rust pitted, its debatable an whether they’re still useful or not. For the amount of work that it takes, I suggest completely disassembling the motor, this will allow you to do proper inspections and evaluations and eliminates guess work.
On that particular motor, I guess the defining feature that would cause me to keep it original is how good the gas tank paint & deck-el are. If they are wiped out or unreadable, then you can refinish the thing from head to toe without hurting anything. Unless you want to preserve bent or broken parts and call it “patina”. The tiller handle and grip look pretty good tho, they are worth saving as-is. The grip is likely to be brittle so don’t get too rambunctious about twisting it to try and pull it off the tiller bar. The exhaust pipe can probably be salvaged, but its likely that you can buy a length of new tubing from McMaster-Carr and replace it. Or scam one from the same parts donor motor that you get a lower unit from.
PM T2
He's livin' in his own private Idaho..... I hope to go out quietly in my sleep, like my grand-dad did..... and not screaming, like the passengers in his car...
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Actually, not all the 4203’s the same. There are some variations on the early motors and #28 would be an early motor. One is the location of the gas cap. Yours appears to be at the front of the tank, as it should be, where most Pal tanks have it at the rear. Fox Grips, on eBay, has the correct top decal for the (your?) early tank. Lower unit gears – usable is what you’ll find in most of these that are still being run. Shimming the prop shaft gear can be helpful but if you listen these things they have a noticeable gear wine. Here is a video link that should answer most of you questioned on the 2 different lower units –https://youtu.be/GXrGse7_s5Y?si=jMjdbz6nNqZpuPAH – All 4203’s should have the carburetors with the banjo fitting. Here is a link to the 2 different carburetors and any service that may be necessary – https://youtu.be/WjH1UVFcdKY?si=Z7C6fM3bcNv5c8z9 – I’m afraid to add any more links as I believe that is what makes stuff go poof.
A "Boathouse Repair" is one thats done without having tools or the skills to do it properly.
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Here is a link to a video on the magneto that covers the lost spark issue these often have. https://youtu.be/Sn0b0o_tJxQ?si=meCC8YXjb74K7_zu I need to complete the one I’ve started on how to make an improved, thick wall, exhaust pipe to replace the thin wall one that dents so easily. Really easy to do. I also have this video from this summer I need to get finished.
A "Boathouse Repair" is one thats done without having tools or the skills to do it properly.
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