Removal of carbon in exhaust

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Dustinfish

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Re: Removal of carbon in exhaust

So cleaned everything out, compression test was good but the problem seems to be when I put the top of the cover on, the engine runs like crap. I can feel exhaust coming out near the bottom of the right side of the engine. I don't if I have a leak or what, but it will run just fine without the top on.
 
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Dustinfish

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Re: Removal of carbon in exhaust

So I took of the side plate and there is a big *** hole? Its not threaded, but looks like its suppose to be there. Right where the mid section bolts to the upper section. I does look like something was suppose to be there but I dont know what.
 
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Dustinfish

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Re: Removal of carbon in exhaust

adamh1281 said:
go online and look at parts list. exploded view of crankcase etc on evinrude parts. but I didn't see a 140 in 2003, did see a 135 though. the johnson website sent me to the evinrude parts site. see what may be missing.
http://shop2.evinrude.com/Index.aspx?s1=6a9rkrj3vddouah94r3cs8lmk4&catalog_id=0&siteid=1
Click to expand...

You gotta go up top and change the engine type to Johnson and you will find 140 but it doesnt show a picture of the mid section. I cant find it anywhere.
 
nwcove

nwcove

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Re: Removal of carbon in exhaust

Dustinfish said:
So I took of the side plate and there is a big *** hole? Its not threaded, but looks like its suppose to be there. Right where the mid section bolts to the upper section. I does look like something was suppose to be there but I dont know what.
Click to expand...

post pics, im sure someone should be able to figure out what the hole is for.
 
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Haffiman

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Re: Removal of carbon in exhaust

It is the plug/hole for the CO sensor.
You should be able to use a Heli Coil.
 
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Dustinfish

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Re: Removal of carbon in exhaust

Think its for states that might require the checking of emissions from engine, maybe even Canada. I don't its going to be think enough to tab it. I need something like a dry wall screw that I can put in the hole then opens up when it gets threw and can take the heat. Then I can just tight down the screw with a rubber washer. Thats going to be hard too cause the hole is about a inch wide.
 
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Haffiman

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Re: Removal of carbon in exhaust

It is not only for emissions check.
The sensor calibrates the injectors to give correct amount of fuel.
Not running the systems might lead to the engine getting leaned out by time.
Engine has to be run a certain time at two different intervals at a given rpm which then sets the fuel mix according to boat and engine load. As mentioned before, there are no 'screws' to set correct fuel mix. Check the color of your plugs. If stating to get too white or fouling, this is the first step.
This might be one of the draw-backs of modern 4-stroke technology. The engine needs the same care and adjustments as the old carbed ones, just a different way of performing it. You have the same system in cars, but there the sensor is permanently installed as it is no water in the exhaust! In an outboard is has to be done 'manually' from time to time but unfortunately not done by most dealers. Neglect it and you can start saving money for a head and valve job in the near future, probably around 1500hrs. Follow it up together with timing belt/chain and valve adjustment checks and 5-10.000 hours should be no problem on the power head.
 
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Dustinfish

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Re: Removal of carbon in exhaust

This plug is shot....done and only way to replace it is to replace the hole exhaust section. I pretty sure this is cast iron, I am not welder but I not sure you can weld anything to it. Only thing I can do is try to get something to cover it. Plus this engine is at 1200 hours so a rebuild is coming soon anyway.

After looking over the manual the only thing the manual stats is emissions check for the state of Californa. Do you have a link to where I could by or see this sensor that plugs in there?
 
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Haffiman

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Re: Removal of carbon in exhaust

The sensor is a licensed dealer service tool only.
The exhaust collector is cast aluminum, but the plug was probably a normal zink-plated plug. Used to have a lot of problems with the same plug on 60/70 4-strokes I sold and serviced. Normally pulled them and often replaced them every year.
Great engines when running, but I doubt you will find anyone on the this board in 20-50 years like today with the old 2-strokes. They need a lot more service and care than most owners and even mechs are aware of.
The local taxi boats and island hopping boats are starting to revert back to the old Enduros from Yamaha that lasts at least 10+ years. Max for the 4-strokes are 4 before expensive troubles starts.
 
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Dustinfish

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Messages
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Re: Removal of carbon in exhaust

Haffiman said:
The sensor is a licensed dealer service tool only.
The exhaust collector is cast aluminum, but the plug was probably a normal zink-plated plug. Used to have a lot of problems with the same plug on 60/70 4-strokes I sold and serviced. Normally pulled them and often replaced them every year.
Great engines when running, but I doubt you will find anyone on the this board in 20-50 years like today with the old 2-strokes. They need a lot more service and care than most owners and even mechs are aware of.
The local taxi boats and island hopping boats are starting to revert back to the old Enduros from Yamaha that lasts at least 10+ years. Max for the 4-strokes are 4 before expensive troubles starts.
Click to expand...

Did you every have one where the plug hole is shot? What did you guys do? Its alot of work to replace the exhaust adapter plate.
 
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Dustinfish

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Re: Removal of carbon in exhaust

So for a temp finsh I got a metal dry wall screen that has one of those V nuts on the back that expands once it gets threw the hole. Got a couple of big washers and used a whole bunch of RTV black ultra to seal it off. Works like a champ up to 3000 RPMs. Going to have to test tomorrow in the water but I think it shouldn't have a problem till I can find a better idea. Thanks for all your help guys.
 
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Haffiman

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Re: Removal of carbon in exhaust

Sometimes just changed 'up' one size going from mm to inch in threads. Plumbers or hardware stores have plugs in different sizes that may fit.
pipe-plug2.jpg
 
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Dustinfish

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Re: Removal of carbon in exhaust

Haff there wasnt any threads left...nothing at all plus the hole itself is in bad shape.
 
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