Universal 5424 cooling hose size

[tseibert]

I'm in the process of replacing all engine Hoses on my 1981 5424 Universal Diesel, The hose on the port side from the heat exchanger to the engine was a breaded cover wire reinforced hose, I assumed was either 3/4 or 1". Naturally it seems like 7/8" which seems sort of non standard. I tried heating a 3/4 inch and it's to small and the 1" seems way to big and I'm reluctant to chance it. Has anyone ran into this issue yet. and have any suggestions.
Thanks in Advance

[rstraebel]

I have the same engine and just put in a new 3" heat exchanger and new hoses. They are 7/8 and I got hose at West Marine. They apparently don't make 7/8 fittings, so at the "other end' I took a 1" hose barb and ground it down to 7/8 OD (more or less) my boat yard - a good one - told me they do it all the time. I'll bet the 7/8 is actually some metricc size. Call me if you want [phone] (home) in Maryland. Sounds like we have the same setup. I am dealing with the intermittent start button issue right now. Good luck.

[tseibert]

Thanks for the reply and info, I was able to get the 1" hoses to work but required dual hose clamps to stop the drips, so far so good. I'll be interested to hear about your 3" heat exchanger as I've heard the 2" may be undersized for southern sailed boats. I may be able to help with troubleshooting the start button. (I have the same issue). Mine seems to be intermitten and the first time if failed, I scrambled down to the starter motor with a jumper wire and attached one end to the solenoid (yellow spade lug) and then touched the other end to the positive (large red) on the starter solonoid and the motor cranked over fine and and started fine. Further investigation reveled a corrouded spade fast-on on I replaced the faston and shortened the wire as the wire was a bit green also. Thought I had it but it still occurs occassionally but I'm always able to jump the solenoid at the starter and it will turn-over. This weekend I went to the starter button itself and by jumpering across the terminals I always get it to trun-over. So I belive my switch is bad, I found a repleacement push-button at John Featherman's web site and plan to order one. BTW John has been a great source for me for 5424 advice and parts, He ships quick answers emails daily, I would highly recommend him (I have no affiliation but appreciate and support good customer service)

[rstraebelmackinac]

tseibert, we seem to have a lot of common problems with our 1981 5424's.

Regarding intermittent start switch, my hit or miss troubleshooting approach was : [1] Had my batteries checked out and equalized ($0) - they were good - still had the problem, [2] Replaced starter button switch -West marine stocks them ($20) - still had the problem, [3] Replaced battery cables ($300) - yes, my yard charged me that much to fab them and i still had the problem, [4] Rebuilt starter and solonoid at a local starter shop ($180) - seems to have finally fixed it.

My feeling is that there is a lot of chatter on this issue, but it was the solonoid.

Universal does not sell a solonoid for the 5424, only an entire starter assembly for $900. My yard said they NEVER order OEM starters for old engines but always rebuiild. That's my recommendation.

By the way, I am headed out for the summer to cruise Long Island and vicinity, see you in August!

[tseibert]

Good advice on the rebuild at the local shop, So far this season mines been starting better but not perfect. (max 5 button push's), I did clean the connections up in the 8 wire wiring harness over the winter. Hope you have a great crusing season, So far no leaks for me in the 1" water cooling hose