Thank you for the information. You can skip the rest if you want, long story short I have two motors, one rebuilt with an overheating problem (heads warm, tell tale cold and flowing) and the other I put a piston in that is finally working as it should. I'll check more as soon as I have a chance.
I'm dealing with an overheat issue now too, and at least I have a few more things to check. I'm a med/heavy truck tech, and these small 2 strokes are not what I'm good at. I bought a rebuilt 1993 115 evinrude last summer/fall. Took him longer than anticipated to get it done, meanwhile I bought a 1992 115 johnson with a bad #1 piston. I replaced the piston, honed the cylinder, and reassembled that engine in time to use it last summer, and it worked great. Finally got the rebuilt engine and only had time to get 2 hours of breakin done before I got too busy in fall. Got the rebuilt motor out a few weeks ago, restarted, and finished the break-in, everything seemed fine on my fishing boat, while the other motor I took apart would only rev to 2000 rpm on my pontoon. Switched motors, and used the rebuilt one on my pontoon, for an hour of cruise, stop, fish, cruise, stop, kids swim, cruise, stop, fish, etc. Worked great. Took it out the next day, and made it about 5 miles across the lake cruising around 16 mph turning 4000 rpm, when the overheat alarm went off. Cold water coming out the tell tale, heads very warm to the touch. Limped it back, still not sure what happened. Guy that rebuilt it says either the new thermostats failed or something got sucked up and plugged something internally. I haven't had time (or wanted) to try to take the thermostats out.
Haven't found much to go on until I hit this thread. So I swapped the ign parts and tried out the other motor on the fishing boat. Worked great. So when the new power pack and coils get here they can go on the rebuilt motor and I can try and find the overheating problem. Since I sold my old fishing boat 3 years ago with the '86 evinrude 50hp, I have had nothing but problems with boat motors. So I don't know how long the fishing boat will run well and be usable, but I'll take what I can get. It was very windy today, so we went skipping across the waves at 37 mph and pulled a 3 person tube at 20 mph easily with the fishing boat and the motor I replaced the piston in. I figured for the little money I have into that motor versus what I paid for the rebuilt one, It's well worth the money.
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There's a youtube vid i saw showing it being done still attached to the motor, while still attached to the boat....not neccesarily believing everything i see on the internet....that IS this mornings 1st project