1997 200 HP Johnson with spun cylinder sleeves???

A local mechanic called this week to inform me that my 1997 200 HP Johnson Outboard had two cylinders with spun sleeves. This was the explanation for the low RPMs that I discovered earlier in the season that prevented the boat from getting on plane. I am very surprised with this diagnosis, since the motor has always run flawlessly, and I only started it 3-4 times in the driveway the last two summers, and then with ears that produced a moderate flow of water from the rear of the engine.

I have never super-heated or abused the engine, which is apparently the cause for sleeves to spin. Can running the engine for 5-10 minutes in a driveway with ears on at low idle cause an engine to overheat? Is this a common occurrence with older Johnson outboards? Lastly, can a journeyman level mechanic successfully make this repair? The mechanic has mentioned a $3,000 repair bill, and I have no confidence that the same thing won't happen again, especially since there is no reasonable explanation for the original cause.

Any insights and commentary would be appreciated.

Dennis

Re: 1997 200 HP Johnson with spun cylinder sleeves???

Having been in this line of work since around 1960, retiring in 1991, I have never (NEVER) heard of a cylinder sleeve spinning.... and I would be greatly surprised to find that any other certified technician has either.

Are you sure that the mechanic said "spin"?

Re: 1997 200 HP Johnson with spun cylinder sleeves???

Throw the bare block in the oven and heat to 450 for 1 hr. Put on thick gloves and move the sleeve back to where they need to be.

Two things cause them to spin..........Overheat and lack of interference fit. I have seen more than a handfull that had less than .0015 diff between sleeve and block.

If it is the latter, the only fix is, bore the block and go with oversize sleeves.

Straighten it back out, put it back together and give it a whirl.............. It aint rocket science!

Re: 1997 200 HP Johnson with spun cylinder sleeves???

Verify for yourself the diagnosis. He has the heads off, compare sleeve positions in all cyls.

Re: 1997 200 HP Johnson with spun cylinder sleeves???

I've heard of this happening but I'd take it to another tech or machine shop to verify it. As the old saying goes, when a doctor gives you an opinion, get another one.

Re: 1997 200 HP Johnson with spun cylinder sleeves???

Joe Reeves said:

Having been in this line of work since around 1960, retiring in 1991, I have never (NEVER) heard of a cylinder sleeve spinning.... and I would be greatly surprised to find that any other certified technician has either.

Are you sure that the mechanic said "spin"?

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I google searched 'outboard spun sleeve' to find out what the heck a spun sleeve was....and found this.
http://www.marineengine.com/boat-forum/showthread.php?379172-Spun-cylinder-sleeves

Re: 1997 200 HP Johnson with spun cylinder sleeves???

My apologies for the delay. Yes, The mechanic told me that the sleeves had spun, and were not in alignment with the exhaust and intake ports. In his opinion, that was the reason the motor wasn't able to exceed 3,000 RPM under load.

Re: 1997 200 HP Johnson with spun cylinder sleeves???

Joe,

My apologies for the delay in responding. Yes, the mechanic told me that the sleeves had spun, apparently moving the exhaust and intake ports away from their normal orientation.

Dennis

Joe Reeves said:

Having been in this line of work since around 1960, retiring in 1991, I have never (NEVER) heard of a cylinder sleeve spinning.... and I would be greatly surprised to find that any other certified technician has either.

Are you sure that the mechanic said "spin"?

Click to expand...

Re: 1997 200 HP Johnson with spun cylinder sleeves???

This is not a new problem, I have my son's 200 mercury in my work area with a rotated sleeve in # 1 cylinder. Will need to send it to a machine shop with a new sleeve for installation. I think the term "spinning" is wrong, the sleeve actually rotates out of phase with cast in ports.

Re: 1997 200 HP Johnson with spun cylinder sleeves???

Johnrude had problems with this in the 1993 loopers as the interference fit was bad and they actually installed thicker sleeves to fit the production run of blocks. It is not a common problem but it does happen usually if the engine as been run a log time at the verge of overheating. I would like to see picture of misalignment as the ports dont match/line up good from the factory anyway, and I dont think this is your problem for engine rpm loss. It would really have to close off some exhaust and intake ports to cause this and if they rotated that far the ring ends would fall in the ports and break...

Re: 1997 200 HP Johnson with spun cylinder sleeves???

Bingo - the sleeves do rotate that far and the rings do "grab" the ports. Exsample my Son's Merc. 200.

Re: 1997 200 HP Johnson with spun cylinder sleeves???

194269 said:

This is not a new problem, I have my son's 200 mercury in my work area with a rotated sleeve in # 1 cylinder. Will need to send it to a machine shop with a new sleeve for installation. I think the term "spinning" is wrong, the sleeve actually rotates out of phase with cast in ports.

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Thanks for your comments.

I was thinking of doing the same thing and considering this a father/son project. Do you think a journeyman level mechanic can take the motor apart and send the block out for repair, then put the motor back together again?

Dennis

Re: 1997 200 HP Johnson with spun cylinder sleeves???

Thanks for your reply. I too have my doubts for the misaligned sleeves as the cause for low RPM. I am thinking about paying the mechanic for his troubles and bringing the boat home as a winter father/son project.

Dennis

Faztbullet said:

Johnrude had problems with this in the 1993 loopers as the interference fit was bad and they actually installed thicker sleeves to fit the production run of blocks. It is not a common problem but it does happen usually if the engine as been run a log time at the verge of overheating. I would like to see picture of misalignment as the ports dont match/line up good from the factory anyway, and I dont think this is your problem for engine rpm loss. It would really have to close off some exhaust and intake ports to cause this and if they rotated that far the ring ends would fall in the ports and break...

Click to expand...

Re: 1997 200 HP Johnson with spun cylinder sleeves???

ChapelARMS said:

Thanks for your comments.

I was thinking of doing the same thing and considering this a father/son project. Do you think a journeyman level mechanic can take the motor apart and send the block out for repair, then put the motor back together again?

Dennis

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Yes. Years ago I had johnson 70 resleaved at LA Sleave in Los Angeles. I think it was $200 per clyinder I had all three done. They did excellent work.

Re: 1997 200 HP Johnson with spun cylinder sleeves???

jayyyy said:

Yes. Years ago I had johnson 70 resleaved at LA Sleave in Los Angeles. I think it was $200 per clyinder I had all three done. They did excellent work.

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Thanks, that definitely gives me some inspiration.

Thanks for your reply and commentary.