Re: water running out my spark plugs
I ran into this problem with my 1988 engine I was not able to get the engine to run any higher than 4400 rpm and there was light water spots on spark plug of cylinder #3 well I ended up pulling the heads once I completed compression check I was getting about 120 psi on all cylinder except the one with the water on plug when i pulled the head plates did inspection of the cylinder and I had a pin hole in the cylinder going through bore into the cooling jacket. I was told that I can re sleve the cylinder and then the engine would run unbalanced or rebuild the engine well needless to say I now have the engine for sale if anyone wants to work on this awesome engine that I am attached to 1988 200hp blackmax.
I am not saying that this is what is happening with your engine but it is something that you can check good luck let us know what happened
If you sleeve the cylinder, you run a stock piston in it. As long as the porting is matched, it would not run off balance. It's a common repair, and perfectly legitimate. If you re-ring, just be sure you get the rings for steel cylinders for that hole. Break it in as if it were a steel sleeved motor.
These engines are basically so wild to start with that you can put an oversized piston in one hole and not notice any imbalance. It just isn't enough difference to matter.
If the shop is worried about "imbalance" it's because they bore them crooked. Go somewhere else.
There are experts who hang out on the hot rod sites, like Scream and Fly, that could weld it if they can get at the back side of the leak. They probably could even cut through the water jacket, repair the cylinder, and repair the water jacket.
A guy that comes to mind is Ruck. 1 920 233 3833 in Oshkosh, Ws.
hope it helps
John