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Replacing melted piston 91 Evinrude 150 XP

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  • Replacing melted piston 91 Evinrude 150 XP

    I recently purchased a 92 Nitro 180 that has a 1991 Evinrude 150 XP. Performed a compression check and the bottom left cylinder was at 70 (Bottom Left looking from the back of the boat to the front) all others were 95-100. I pulled the head on that side and the piston head is melted. The head and cylinder walls look good. I see no other damage. Wondering if I have to pull the entire block to replace the piston or can I pull the carbs and reed box to R&R the piston with a new one? Engine Model Number: TE150SLEIE


  • #2
    Re: Replacing melted piston 91 Evinrude 150 XP

    I'm gonna say yes , you need to pull the powerhead off and split the crankcase to get at the connecting rod, head will have to come off.
    sigpicSignature- If you have fuel and spark- Have you checked compression?

    Comment



    • #3
      Re: Replacing melted piston 91 Evinrude 150 XP

      Also looking for a used regulator and stator for this motor or an entire motor for parts if the price is right.
      Part Numbers:
      Regulator: 0395204
      Stator: 0584292

      Comment



      • #4
        Re: Replacing melted piston 91 Evinrude 150 XP

        When you have it apart, to replace the one piston-I'd re-ring the other 5 pistons. You should find out the reason for the failure or it will happen again on the new powerhead. Pull the carb apart that feeds that cylinder and check the jets on that side of the carb. May be debris in them causing a lean condition...

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        • #5
          Re: Replacing melted piston 91 Evinrude 150 XP

          We started the boat before the purchase (water hose hookup while on the trailer). It started, idled and revved fine. Two weeks later got a chance to drop it in the water for a test run and all it would do was putt around. Anything more than Idle under load and it would die. Pulled it back out pulled the cover and that's when I noticed the wires on the regulator were burned/melted. It didn't smell or look like it had just happened. The regulator looks like it actually caught on fire and burned the bottom of the stator. The guy I purchased the boat from said it ran fine last time he had it out but that was over a year ago. I need to replace the regulator and maybe the stator, clean all the carbs and since I have to pull the case to replace the piston I'll probably re-ring all 6 pistons. Should I look for another engine and part this one out or drop another $1,000 plus in and hope for the best?

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          • #6
            Re: Replacing melted piston 91 Evinrude 150 XP

            Well, you may have learned something useful here. Running an outboard w/o load on the hose tells you nothing about it's condition, other than it will start and run. No way the motor "ran fine last time he had it out" in the condition you bought it. emdsapmgr has it right ... find the exact cause of the burned piston, or it will surely happen again. If you've never done a major rebuild before, get an OEM shop manual, which will explain exactly what you're in for, then decide whether you want to rebuild or get another motor.
            Jim

            ===============================
            I don't respond to Private Messages PM's that are motor questions.

            For basic information on a wide range of topics, see Top Secret File
            Link: http://forums.iboats.com/showthread.php?t=299680

            OEM shop manual: outboardbooks.com or Ebay

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            • #7
              Re: Replacing melted piston 91 Evinrude 150 XP

              Thanks for the help. I've got the manual on order as this will be my first outboard rebuild. I rebuilt a few car motors when I was younger but no outboards. Any gotcha's I need to look out for?

              Comment



              • #8
                Re: Replacing melted piston 91 Evinrude 150 XP

                No overhead cams, timing chain/belts or valve trains to deal with.
                2 strokes are a lot simpler, you need to find a marine engine machine shop to do the piston/block fitting.
                Rebuilders around Boston charge $3K for 6 cylinder, complete rebuild and test run with guarentee, going diy will be a lot cheaper.
                If you rebuild it, you'll know exactly what you've got, you aren't going to find a motor that runs like new for that money.
                sigpic
                See FAQ Files.
                http://forums.iboats.com/showthread.php?t=299680

                Get the genuine factory service manual.
                www.outboardbooks.com
                www.*****************

                Comment



                • #9
                  Re: Replacing melted piston 91 Evinrude 150 XP

                  Before you tear into it find out what caused the damaged piston. Otherwise you may be in for a repeat performance.

                  Comment



                  • #10
                    Re: Replacing melted piston 91 Evinrude 150 XP

                    A factory service manual is almost a requirement on any rebuild. You can contact Ken Cook Co., in Milwaukee for the exact one you need.

                    Comment



                    • #11
                      Re: Replacing melted piston 91 Evinrude 150 XP

                      I would think the carb was the problem but won't know till I dig into them.

                      I've got the factory service manual coming.

                      My game plan:
                      a. Replace bad pistion w/new pin
                      b. Hone all cylinders
                      c. Replace rings on all pistions
                      d. Replace Reg/Rect
                      e. Clean Carbs (Repair if needed)
                      f. Replace spark plugs
                      g. Test Stator (Replace if defective)

                      I'm I missing anything?

                      Thanks...

                      Comment



                      • #12
                        Re: Replacing melted piston 91 Evinrude 150 XP

                        Check your crank and bearing conditions as well as measurements. You will need a full gasket kit as well and while its apart you may as well do the thermostats.
                        sigpicSignature- If you have fuel and spark- Have you checked compression?

                        Comment



                        • #13
                          Re: Replacing melted piston 91 Evinrude 150 XP

                          how long or how high did you rev up the motor on the hose? that could have got it hot and caused the problem, did that myself to a 135hp Johnson a long time ago didn't know then that you wasn't suppose to go wide open throdle while on muff's. Learned my lesson the hard way broke a ring and beat up the piston

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                          • #14
                            Re: Replacing melted piston 91 Evinrude 150 XP

                            When you overhaul the carbs, use an aerosol carb cleaner. Blow out the passages with it and check the spray out of the exit orfice from each passage. Compare the spray from one carb passage with the spray flow from the same passage on the other carbs. It's not unusual for dried fuel to clog or reduce the passage diameter, causing lean running conditions. Pull all the jets and visually inspect them.

                            Comment



                            • #15
                              Re: Replacing melted piston 91 Evinrude 150 XP

                              When we ran it on the trailer we didn't rev it that much just a little. No telling what he had done previously showing it to other prospective buyers. I want to thank everyone for their helpfull input. I will update this thread with my results as they progress.

                              Thanks...
                              TheStinkMan

                              Comment

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