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    1984 johnson 90hp carb leaking fuel out air cleaner

    The original lower is 321668 and I can't seem to find the upper. but again, that is identical to what I pulled out which is E330. If there is a factory number on it, it is faded and beyond recognition. I am more concerned about the lower seals, is seems I am replacing 1 original seal with two...
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    1984 johnson 90hp carb leaking fuel out air cleaner

    I know seleoc sucks, but as I mentioned, OEM is 4 months out. All 3 seals say TTO on them. part number "d1129" and "d696" for what I assume to be lower, and upper is "E330" which actually looks identical to what I pulled out. Google didnt turn up much for me. I see in WSMs (ebay) instruction...
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    1984 johnson 90hp carb leaking fuel out air cleaner

    I ended up freezing the bearing and heating the upper crankcase head and bearing assembly, also upgraded to a 4lb soft mallot and was able to get it in. Can't be scared of the heat, lesson learned, I was being to overly cautious about damaging parts with the torch. Still would appreciate help...
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    1984 johnson 90hp carb leaking fuel out air cleaner

    Can anyone tell me, or point me to a video, documentation...etc. of how to safely install the upper crank bearing without an arbor press? Also, are the two seals in the attached picture supposed to be used or is one extra, just depends on what one fits?? Thanks
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    1984 johnson 90hp carb leaking fuel out air cleaner

    my take away is I should have asked before attempting? I was fairly confident after reading on the forums specifically faztbullets post where he mentions a torch or oven "If you use a oven set it on top of a small saucepan and it wil drop out in pan when it gets hot enough. Have new bearing on...
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    1984 johnson 90hp carb leaking fuel out air cleaner

    I was hoping I wouldn't need all this hand holding but............ I used the torch method to heat up the upper bearing housing and beat the original bearing out using a socket and hammer. I heated up the housing, applied 2 stroke oil to the inside housing, and the bearing. I have been hitting...
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    1984 johnson 90hp carb leaking fuel out air cleaner

    Wow, took about a minute and had it off. Thank you much!!!!!!
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    1984 johnson 90hp carb leaking fuel out air cleaner

    I am stuck attempting to remove the "Crankcase Head" on the lower part of the crank Part Number 12 so I can replace seals and bearings. My manual skims over this and I can't seem to find any good info on removing. I assume I am doing something stupid. All screws/bolts are removed. The upper...
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    1984 johnson 90hp carb leaking fuel out air cleaner

    There are no manuals in stock, that I could find (4 months out if you order it today), so I am using the manual from boatinfo.no located below. Specifically this page here on 3-33 . Are these factor OEM manuals, I can't see any author or copyright info. They same "ok" but who am I to judge...
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    1984 johnson 90hp carb leaking fuel out air cleaner

    Trying to get started rebuilding piston cyl and rings. However, whats the min and max allowable ring gap should be for rings that are .02" out? The service manual states "The maximum and minimum allowable ring gap is .07-.17" (1.8-4.3mm)" But I can't even find a feeler gauge that goes up to...
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    1984 johnson 90hp carb leaking fuel out air cleaner

    Thanks for that explanation, makes complete sense. I see those power head rebuilt kits by wsm and Happiemac on ebay. Happiemac is a bit cheaper, but WSM seems to be prefered on this fine forum.
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    1984 johnson 90hp carb leaking fuel out air cleaner

    Yep, I know. I can find .030" everywhere, but it was advised for me to only go .020" out. I found a complete powerhead rebuild kit on ebay that allows you to select .020" out.
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    1984 johnson 90hp carb leaking fuel out air cleaner

    Would you advise on NOT going 0.030 inches out, it seems piston and ring kits are easier to find for this rebore size. 0.020 inches is not as common, from what I am seeing. Thank you
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    1984 johnson 90hp carb leaking fuel out air cleaner

    Great!! So do I need to bore the cylinders and go .030 OVERSIZE, or hone the cylinder just stick with replacing with new standard size piston and rings. Thanks for your help!!!!!
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    1984 johnson 90hp carb leaking fuel out air cleaner

    I am glad to here that. No need for a new block........had me worried, seemed costly at $3500 and every site was out of them except used on eBay. The pistons markings on the inside are 49003-a , 328 355. They all measure right around 3.5. Does O/S mean original standard??
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    1984 johnson 90hp carb leaking fuel out air cleaner

    Yes, it seems the manual stresses he importance of compression testing, then if any cylinder is not within 5psi, take it all apart.. What are my options please. Or are you saying this is no longer salvageable.
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    1984 johnson 90hp carb leaking fuel out air cleaner

    Just showing the exhaust visual state. Disregard Finally got it apart, see attached pics. Stuck bottom ring on the top starboard piston. Top ring took chunk out of the bottom starboard piston.
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    1984 johnson 90hp carb leaking fuel out air cleaner

    I have been reading the service manual from johnson evinrude from boatinfo.no , a lot to get through but interesting for sure. Some more pics of the other piston and part of the cylinder. This is actually the port side that compression was at 120psi. The exhaust is.......wow....
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    1984 johnson 90hp carb leaking fuel out air cleaner

    If you look at post number 3, see gash in carb image here . This does not appear to be an idle circuit as I believe they are on the other side of the throttle valve.
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    1984 johnson 90hp carb leaking fuel out air cleaner

    is the reason there was gas leaking, due to the lack of compression on the starboard side cylinders? Or do I have more carb work ahead of me????
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