KG7 Water Pump Cover Removal

[green-thumbs]

Be gentle, any method that preserves the thread in gear case is a good method AND any method that messes up the gear case thread is BAD.
The cover is stuck either because it was installed tightly OR because
threads are corroded…most likely corrosion ,which may mean the
thread strength is compromised. Some combination of heat, solvent
and percussion may unlock the corrosion locking cover thread to
gear case thread allowing the cover to be worked loose and removed,

A cover with clean thread and a gear case with clean thread (both
greased) can be installed and remove with only finger pressure,,,no
special tool needed. The difference between the effort needed to remove a stuck cover and a cover that is easily turned has to be
either the force used to install it or corrosion, If you are going to have
a replacement cover made the old cover can serve as the pattern
to follow in machine the replacement. Easier if the cover is intact not
in fragments.
Gear case and covers for KE4 thru KG4 vary in some details ,but, share the same thread. and same problems.
Louis
.

• This reply was modified 4 years, 3 months ago by green-thumbs.

[bkrsdoz]

I had soaked and heated the cover for several days.
I clamped the tool on so it could not ride up on the holes in the cover and slip.
Both pins snapped off clean on the tool, and the cover didn’t budge.
I will reluctantly drill out the cover as suggested, and collapse the remnants and remove it the hard way.
I now recall why I really like the vintage Johnson’s and Evinrude’s!
There is nothing quite like a KG7 whining on the back of the boat though!
I’ll keep at it and will be successful.
Thanks for the photos and suggestions.
Bob

[green-thumbs]

Be gentle and patient. ‘
Louis

[jeff-register]

Righty tighty…..NOT Lefty tighty Righty lucy
I used steam fitting anti seize joint compound on the threads.

• This reply was modified 4 years, 3 months ago by jeff-register.

[pugsmanias]

I’ve had to do that! Even with all the correct tools I have, sometimes you have to get medieval on it. Anti-Seize is a great suggestion.

[The Boat House]

• This reply was modified 3 years, 2 months ago by The Boat House.

[lloyd]

I made the tool for my KG7 and it worked great. It will be included with the motor along with a selection of stock and speed props and my custom made connector for OMC cable steering if anybody wants to buy the motor. It ran great on my Alumacraft Model R, but I like my OMC 18’s with a speed prop on that boat. 231-929-7479 I am on a cruise through the Panama Canal right now so I will not be home until sometime in February.

[Buccaneer]

lloyd wrote:

I made the tool for my KG7 and it worked great. It will be included with the motor along with a selection of stock and speed props and my custom made connector for OMC cable steering if anybody wants to buy the motor. It ran great on my Alumacraft Model R, but I like my OMC 18’s with a speed prop on that boat. 231-929-7479 I am on a cruise through the Panama Canal right now so I will not be home until sometime in February.

Lloyd, what kind of outboard are you using on your cruise? 🙂

Prepare to be boarded!

[20mercman]

I have taken dozens of these out, and never had one that I couldn’t get. I too feel lucky, but I have used the tap around the cover method before. I did have a Mk-25 water pump cover that I had to drill out, but that has been it.

Steve

[lloyd]

Buccaneer. I would have used my Model R but I had my wife with me so I took my larger Alumacraft with twin 57 Javelins. Just kidding. We were on a Norwegian Cruise ship with an old friend from Upstate New York. Swam with sea turtles on the coast of Curacao, docked in Fort Lauderdale, visited old friends near Tampa, Piloted a Star Wars Cruiser at Disney World, etc. and then flew home to Michigan. We fortunately missed the Covid-19 mess on our trip, but it’s been like the Twilight Zone since we got back.

[Author]

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