At the end of last season the boys complained that the boat had lost power. I checked it out and found number one piston was way down on compression, and water was leaking badly from the exhaust covers in the lower starboard side of the engine.<br /><br />Teardown revealed that the top ring on number one was 'gone' the bottom ring is stuck, the cylinder is scored, and the piston chewed up. I probably only found about 10% of the ring. I think the cylinder and ports will clean up, I'm guessing .030 o.s., but I'll wait to order parts until the machining is done. The bottom ring on number three is stuck with carbon. The gasket between the exhaust plates had migrated and was torn at the location of the large 1/2 inch diameter passage at the bottom where the pick off nozzle is. The thermostats check out opening at approx. 145 F. The bearings and all rotating parts are shiny and clean. I put cast carb float bowls on the motor about six years ago after the plastic ones warped.<br /><br />In past years we ran with a 19 pitch prop, and in the last few went to a 17 pitch to get more hole shot. I decarbon the engine and fog it every year, so I'm not sure why the carbon had built up on the rings. The boat hasn't had as much of the hard use the past three years that it had when my boys lived at home and used it everyday.<br /><br />1) Any suggestions as to a good carbon remover while the engine is apart?<br /><br />2) Can I rebuild with the old bearings, since they look so darn good and spin nicely?<br /><br />3) Does the crankshaft seal kit come with the large o-rings?<br /><br />4) What is the favorite for assembly lube, gasket compound and Assembly Seal (between the crankcase and the block)? How should they be applied?<br /><br />5) Do I have to get the 'blue' cylinder head gasket residue off the cylinder heads and block?<br /><br />6) Can I go with new standard rings in the three good pistons, and oversize piston and rings in the cylinder which needs to be bored out?<br /><br />thanks,<br />fp
