john_zilla12

i have a 1979 140 hp evinrude model 140943r. i just tore the engine down and found the exuast fillers broken and unservicable. i just looked into a forum and its been said that these exaust fillers are not needed. is this so? if left out will it change the exaust backpressure and effect performance. how about overheating, excess noise. ive had alot of time playing with tuned pipes on two cycle engines on my remote control race boats. when you extend or shorten the exaust pipe length it changes top and or low end power. without the exaust fillers does this act the same way?

Re: john_zilla12

The engine will run okay without the fillers BUT since they are a vital part of the tuned exhaust setup, removing them will naturally affect the hp rating..... how much, I have no idea.

New fillers will extend somewhat above the crankcase surface so they will require milling at a reliable machine shop in order to be perfectly even/flush with the surface of the crankcase/block.

Re: john_zilla12

Joe Reeves said:

The engine will run okay without the fillers BUT since they are a vital part of the tuned exhaust setup, removing them will naturally affect the hp rating..... how much, I have no idea.

New fillers will extend somewhat above the crankcase surface so they will require milling at a reliable machine shop in order to be perfectly even/flush with the surface of the crankcase/block.

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ive been looking online for the exuast fillers but im having no luck at most evinrude parts sites. do you have any sources? also you mention the fillers need to be milled. when installed are they milled flush with the top of the exaust at the top of the block so it mates with the exaust manifold when the gasket is installed? also this boat was flooded which is why im rebuilding the motor. ive noticed where the connecting rod needle bearing had rusted and slightly pitted the crank. ive cleaned the crank with a soft scrungy pad and cleaned up the surface rust nicely but where the needle bearings sat on the crank it is pitted just a little. you can barely feel it but its there just the same. ive reused cranks with a bearing shell with good results but never with needle bearings. im thinking of regrinding the crank. are oversize crank bearings available? ive also had problem removing the head bolts and snapped off four bolts on each head. one head has a broken bolt boss and will need to be replaced and i may have to sacrifice the other head to save the block. are heads available. ive checked many sites and all i find are the head covers and not the cylinder heads. i also need a source if you know anyone. when you purchase a common rebuild kit for this engine im wondering if this component comes in the kits. on the crank at 4 places there is a huge steel ring. two of which were rusted into the crank. the crank grooves cleaned up well but i think it would be wise to replace these rings. are they included in the kits? thanks, john_zilla12

Re: john_zilla12

You asked "you mention the fillers need to be milled. when installed are they milled flush with the top of the exaust at the top of the block so it mates with the exaust manifold when the gasket is installed?"

Yes, they are milled flush with the present surface of the crankcase/block. If new fillers are not available, you could try good used ones and hope for the best. They would be no worse than what you preasently have. Many have gone that route with excellent results. Should I have any, I'll get back to you here.

Re: john_zilla12

Joe Reeves said:

You asked "you mention the fillers need to be milled. when installed are they milled flush with the top of the exaust at the top of the block so it mates with the exaust manifold when the gasket is installed?"

Yes, they are milled flush with the present surface of the crankcase/block. If new fillers are not available, you could try good used ones and hope for the best. They would be no worse than what you preasently have. Many have gone that route with excellent results. Should I have any, I'll get back to you here.

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thanks alot... im sure ill have a few more questions in the future... i hope you wont mind answering them... john_zilla12

Re: john_zilla12

On a V-4 cross V you could burn a piston with out them installed. On a V-6 cross V you can get by with out them.

Re: john_zilla12

thanks alot... i was concidering the idea of running without exaust fillers... i saw on another forum that one guy said that performance would be slightly better (higher rpm). im playing by the rules and dont want to lose hp or burn a piston... ive found a machine shop that will mill the fillers... i just need to locate them...

Re: john_zilla12

john_zilla12 said:

thanks alot... i was concidering the idea of running without exaust fillers... i saw on another forum that one guy said that performance would be slightly better (higher rpm). im playing by the rules and dont want to lose hp or burn a piston... ive found a machine shop that will mill the fillers... i just need to locate them...

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The filler block kit is part number 392000, about $180.00 or so. Hopefully you can find a good used pair that will come close to being flush with the block surface.