Evinrude 1983 60hp low compression

[Bosunsmate]

Yes dont try a wrench on those head bolts, you will round off the edges and then you will be in really big trouble. All you need to buy is just a socket that fits that size bolt. Buying that is way cheaper than even just an hour at a mechanics and it will last you a very long time.
The water cover jacket needs to come off so you can inspect the thermostat so you havent wasted your time doing that either

 

[DrDim]

No problem I was planning to go to my mother and borrow socket wrenches, torque wrenches and a gummy Hammer. My father was a electrician when he was alive, so there's no shortage of tools. Will give it a new try during the weekend (I'm at home with our daughter so it mostly nights that I have time for this). I was going to ask about the location of the thermostat because I read that there is good practice to change it when doing an overhaul.

 

[Bosunsmate]

yes its down the bottom, take note of its position and also the red thing next to it which has a spring on it, thats called your poppet valve, it opens at high speeds to allow more water to cool the motor. You need to look at it carefully to make sure its not heat warped.. I just test the thermostat in a saucepan, if it works it saves quite a few dollars

 

[Bosunsmate]

No Title

What you definitely have to do on this motor when you have the head off is a reconfiguration of the cooling system. Johnson/Evinrude built these with a design fault. They allow air bubbles to get trapped at the top of the motor, so you just move the outlet from engine for the tell tale to a hole you drill on top of the motor.
Heres mine, you can see the outlet now under the lifting eye.

and heres a link to te service bulletin on it
http://forums.iboats.com/forum/engi...aq/228380-johnson-evinrude-adding-a-tell-tale

But dont bother yourself with that now, first job is to inspect those cylinders/pistons/gasket

 

[DrDim]

No Title

A couple of days ago I tried again but had a failure again with one bolt, however today I tried again with more tools and finally was able to remove the head (I had to remove the 10 bolts + 2 extra in the bottom). The head gasket is blown as you clearly can see in the pictures here. I haven't opened the water jacket yet and one cord is still connected to the head, I can move it around though. There's also a hole in the bottom where one of the two extra bolts is (with some rubber for removing vibrations I guess). So what's the next step, what do I need except a new head gasket?

 

[racerone]

Compression numbers don't lie.---Not surprised to see a blown gasket.----Those rubber mounts are there to hold the lower cowling.---------Any more pictures of the cylinder walls.---Looks like issues are starting to show , possible light scoring.

 

[DrDim]

Have a couple of pictures but these were the best. I thought the cylinder looked nice, didn't see any scratches and it felt smooth.
If there's scoring is the only fix to drill? Do I need sealant for the head gasket?

 

[Bosunsmate]

You need to look at your thermostat and poppet valve in the back of the head and check them over.
No most head gaskets come with the proper sealant.
You also need to move the telltale to the top of the block before you install the head back on, failure to do that will result in another blow out

 

[DrDim]

How much torque should be user when reassembling the head and is there a specific order? Which thermostat do I need?

 

[Bosunsmate]

How much torque should be user when reassembling the head and is there a specific order? Which thermostat do I need?

check thermosta opens in hot water, hold it n a saucepan and heat it up.
yes pattern is from inner to outer like starting in the centre of a spiral and going outwards, the last bolts are the two on the top then the two on the bottom.
I cant remember the torque, i think its around 22ft pounds, someone will know

 

[Bosunsmate]

you need to clean the bolts and the threads in the motor otherwise torque readings will be way off

 

[DrDim]

No Title

The brown cable in the picture is still connected, not sure how I'm supposed to remove that? If I remove all the bolts for the water jacket will I be able to disconnect it? How easy is it to reach the thermostat? Is there a gasket for the water jacket also? As I said before I have a bit of limited time to do this so it would be nice to order some of the parts soon. I have a general repair manual but it's not very specific on where what you need to disconnect.

 

[Bosunsmate]

the brown cable is for the overheat sensor, slide the rubber tubing out the way and you will see the bit that disconnects, thermostat is just behind that cover.
Once you check that then you know what parts you will need to order

 

[DrDim]

Oh alright thanks. I found the value for the torque in the appendix of the repair manual, 216-240 lb which means 18-20 ft lb (24.4-27.12nm we use the metric system in Sweden). I guess I will have to get a toque wrench with small head like 1/4 to be able to fit in the smallest places.

 

[Bosunsmate]

no worries. I use a universal joint adaptor for those bottom two. It cost me $5. Interesting you are in Sweden with one of these 60hps, im on the opposite side of the world, New Zealand with one.
It was so much better on this site when the profiles on the left of posts included where they were from

 

[DrDim]

No Title

Took some new pictures of the cylinder wall, seems to be some light scoring. When should I start to worry? I removed the water jacket cover, how do I remove the thermostat? The gasket for the water jacket needs replacing also. What's the little red thing next to the thermostat? How often should gasket be replaced? What should I use for cleaing up and removing old gaskets, bolts etc?

 

[DrDim]

What parts do I need? I'm having trouble identifying the correct water jacket gasket. Is the red thing the reed valve?

 

[Chinewalker]

No, that is a pressure relief valve. If its not warped or melted looking, leave it be.

As for the scoring - can you feel it with your fingernail? If so, not good.

 

[DrDim]

Ok I will have to check if I can feel it with my fingernail. Is this the correct gasket? http://www.ebay.ie/itm/OMC-315538-E...38-/201353771544?hash=item2ee19eba18#shpCntId

 

[DrDim]

I have checked the thermostat now, doesn't seem to work. Grommet valve, valve pressure relief and spring valve seems ok. I think I'm ready to order the stuff I need, I have seen that you can get sierra and omc parts. Is the price worth it for the more expensive ones (for example the thermostat).

https://www.bootskram.com/thermostat-sierra-18-3543.html?___SID=U Thermostat sierra (cheap)
https://www.bootskram.com/thermostat-ay-5005440-omc-johnson-und-evinrude-ersatzteil.html?___SID=U Thermostat OMC (expensive)

https://www.bootskram.com/gasket-cyl-hd-cvr-315538-omc-johnson-und-evinrude-ersatzteil.html?___SID=U Water jacket gasket OMC (a little bit more expensive)
https://www.bootskram.com/dichtung-zylinderdeckel-johnson-evinrude-35-60-ps-sierra-18-0941.html Water jacket gasket Sierra

https://www.bootskram.com/zylinderkopfdichtung-fuer-johnson-evinrude-sierra-18-3802.html?___SID=U Head gasket Sierra (cheap)
https://www.bootskram.com/gasket-335359-omc-johnson-und-evinrude-ersatzteil.html?___SID=U Head gasket OMC (expensive)

Do they work for my engine? Is it really worth to go for the expensive ones? The reason why I want to buy from Germany is because a lot cheaper shipping and no custom charges. If I order from US I would have to pay ridiculous for the shipping. I haven't found the water jacket gasket in any shops in sweden unfortunatly.