95 Johnson 115HP - Budget Rebuild

[Brock O]

G,Day Gents...again

Only been 4 years since a full rebuild and yet again it has thrown a ring...Phuk me!!!!

Had no signs leading up to it...was running sweat, after failing to start with what i thought was a dying battery and then a dropped coil...has turned into a nightmare with the worse timing. Didn't experience any cylinder locking as such so wasn't expecting this...compression 120, 110, 110....40. Pulled the side cover to see some top ring but unfortunately not complete.

So I've pulled the power head today and rolled down to the shed, looking for advise on a budget build....yes that's right i want this back together with minimal budget...but still with confidence it will hold up.

Water pump was replaced 6 months ago....water diverter's were replaced with new tell tale location so I'm wondering if its still getting a water block as such cursing hot spots or weather the ring has some how caught the exhaust outlets due to wear ? should the exhaust outlets in the cylinder have been slightly smoothed or radius as such to possible avoid this although that does sound imaginary ? The bottom piston has a small dent also which ill photo tomorrow..same story by the looks.

Any way...I'm only wanting to hone the one cylinder at this stage....replace with new piston and rings....head has a few dents but will clean that up and reuse....potently getting this back on the water for $300 or less as i do have a few spare gaskets from last build. What i can or.....or shouldn't try get away with is the question only good old experience can share..

Any advise appreciated.

https://forums.iboats.com/forum/eng...nson-evinrude-outboards/9145634-0-compression

 

[schematic]

running lean. gonna have to find the cause and likely a rebore to oversize. check carbs carefully and replace diverters. Also check for double firing when reassembled.

 

[Brock O]

Oil is pre-mix so rich if anything...just pulled carbies down and all seemed clean and clear. The boat wouldn't sit any longer than a month any time of year.
Timing could be on the advanced side...never had this check by a mech.

Will get the two pistons out...give it z clean and hone and see what you think.

 

[Tassie 1]

Devils advocate time...

2nd budget rebuild looming...

why not save somè time,
dump it
put the money you would spend on it plus what you get for parts sold off it and buy a tested different motor, even if you've gotta wait a couple of months to get a few more $ together,

the old one seems cursed.

 

[Brock O]

Wouldn't call the first rebuild budget...full rebore with all new components...but I do agree with cursed.

will run the gauntlet this time round.

 

[Brock O]

Few pics after pulling it down today...just need right socked to get rod caps off.....think i found the rings and piston pits, or the coarse ? seem the exhaust post was blocked....will have piston out and bore honed in a few days which will decide which way this budget build goes...

 

[Brock O]

Gents,

Bypass covers to cylinders....feed from check valve on inlet manifold.....is this nipple a straight through hole...or is it restricting, can any one tell me ??


Cheers in advnace.

 

[Faztbullet]

A hone wont take that ding out of cylinder will need bored.....looks like Wiseco pistons

 

[interalian]

Gents,

Bypass covers to cylinders....feed from check valve on inlet manifold.....is this nipple a straight through hole...or is it restricting, can any one tell me ??


Cheers in advnace.

The fitting on the bypass covers is clear and of a specific size, likely designed to restrict. The fittings on the intake manifold are one-way valves as you've noted.

 

[Brock O]

No the hone didnt take the dings out...but the two bores did clean rather well, no sharp edges as such so will see if it goes bang or how much comp it loses.

Cheers Interalian....so being a dumbass i figured it for blocked, the open side of the hole is didfferent to the internal size, i have drilled this out to 1.6mm. These are pressed fitted and not available for repurchase...Im looking locally now.

Will need to pull the other bypass cover to try measure the differance.....woundering what affect this would have on the running of the motor ?.