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Disregard. Got it! CMOS :)

@pappy Just about done, but cannot get the lower unit to mate with the main housing. See attached pic. I have the shifter lever in the Neutral position, but I just can't get the lower to insert any higher. Thoughts? CMOS

That's right! The throttle travel is limited in Neutral! Thanks Pappy. I should be able to finish her up tomorrow. CMOS

@pappy Well guys it's been long time since I touched this motor but now that it's getting a bit cooler and the COVID insanity is simmering down I'm back on the job . I'm putting everything back together but noticed a problem when I put the carb back on: When I advance the throttle, the CAM...

Update: Got the Power Head back on the main cowling yesterday, and started the process of getting things buttoned up. Just need to follow the pics I took as I took it apart to keep the right grounds, etc. Pappy CMOS

Pappy Done with the exhaust main tube. It went well. The grommet on the short water tube was getting pretty dry and brittle. I got it off the tube in pieces. The other still looked pretty good and was still flexible. Both were replaced. Right now the only thing I am missing is a Bypass...

The carb was previously done (full kit) by me but since it has been sitting for many months, I do plan to pull the carb and clean all the jets and various channels again. Probably gummed up a bit after sitting so long That carb is pretty easy to do (and that says a lot since I'm a general...

It was OMC, with the metal inserts.... Any comments on the pics above? Normal? CMOS

Pappy Exhaust covers off. Nothing striking that I can recognize. Pappy? Anything look out of ordinary? Note where my thumb is pointing in the one pic. That's a small circulation hole that was plugged with some minerals/junk. Right now I have the Outer and Inner cover plates soaking in...

Pappy Pappy, I do have the grommets already. I will work on those after I finish the Exhaust Cover inspection and gasket replacements. What do you mean about the above comment in Red? Thanks for your help. CMOS

Pappy, I'm curious as to 1) why it sat for 2 decades and 2) what was the impetus to fire her up now? Sounds like she wants to run! CMOS

Back on this now that it's a bit cooler. Today I pulled the Bypass cover just to take a peek at the piston walls on that side. Both looked equal and no scoring of any kind. Repainting the cover while I have ti off... I also replaced the Head Gasket after I resurfaced the Head seal surface...

I really like old motor stories..... CMOS :D

Thanks Pappy. That's what I was looking for - those 2 grommets. I will also replace the exhaust baffle plate gaskets and inspect that inner plate for any possible pin-holes. CMOS

***If*** she's got good and equal compression on both cylinders, you have a great motor. My first motor was a 1966 Johnson 9.5 (identical to yours), and it was a fantastic motor. Never let me down. Ran like a champ and started within 2 pulls regardless if the temperature was 40 degrees or 95...

Howdy All, It's been a while since I worked on this motor but it's time to dig into it once and for all. Here's a link the the old thread: https://www.tinboats.net/forum/viewtopic.php?f=4&t=42830&start=30 Today I managed to pull the power head, which to my surprise lifted right off with...

Howdy All, In preparation for a trip next weekend I pulled the boat out of the barn and fired up the 1998 25HP Merc to let her run a bit. Looks like the carb float was stuck in the down position, as fuel came dripping out of the cowling when I primed the fuel bulb - first time that happened...

OP, Do yourself a big favor - put a "Side Shift" kit in that and never look back. I have a 98 25 HP Marc and had all sorts of trouble with the tiller shifter mechanism. Had a Side Shift installed and all is well and running perfectly. There are far too many things to go wrong with these...

Another angle: If you can find a small metal fabrication shop nearby you may be able to get them to fabricate a coupe for you. I have seen others on this site do this, with great success. A fabricated one doesn't have to look exactly like the old design. It just needs to provide support for...

LT, I have a 66 Lone Star Commander. Darn fine boat. Here's the thought process I suggest you take short term: 1. First decide if you want to miss this summer's fun, or - dive into the repair and do it properly right now. To do this right, you're correct, you'll be down for a while. 2. If...