restoring a 1966 5hp johnson (pics)

[Evinrude Boater]

Re: restoring a 1966 5hp johnson

Re: restoring a 1966 5hp johnson

I'm playin' with the same motor and I don't see an air inlet opening in the engine cover. How does this engine breathe?

 

[samo_ott]

Re: restoring a 1966 5hp johnson

Re: restoring a 1966 5hp johnson

He is 16 he said... and he knows a helluva lot more about Jeeps than outboards! I agree, impressive.

Does anyone know why the 5hp has a 3 blade prop as the 5.5 and 6's had a 2 blade prop. Or is his prop not original?

 

[ezeke]

Re: restoring a 1966 5hp johnson

Re: restoring a 1966 5hp johnson

His prop is different from the 6HP and so is the gearcase.

His propeller should be a 8 X 7-1/2 #380104 if it is the original.

 

[4.0l sahara]

Re: restoring a 1966 5hp johnson

Re: restoring a 1966 5hp johnson

Sahara did I read somewhere that you are 16 years old? If so, you are
an impressive young man. Very intelligent. Correct me if I'm wrong about your age. I'm trying to learn as much as I can about older motors. I'm overwhelled by your knowledge for just a young man. Kudos to you.
Sorry for jumpin' the thread.

I'm playin' with the same motor and I don't see an air inlet opening in the engine cover. How does this engine breathe?

He is 16 he said... and he knows a hellva lot more about Jeeps than outboards! I agree, impressive.

Does anyone know ahy the 5hp has a 3 blade prop as the 5.5 and 6's had a 2 blade prop. Or is his prop not original?

Thanks I'm 15 almost 16. The prop is the correct prop. It's a nos one I got on ebay.

 

[4.0l sahara]

Re: restoring a 1966 5hp johnson

Re: restoring a 1966 5hp johnson

Took it to school and did a little work to it. Pulled the flywheel. Coils look good. Took of the head and water jackets were full of junk. The cylinders look real good no scoring just normal wear. The rings look nice too. This engien had alot of compression too.

pics

 

[4.0l sahara]

Re: restoring a 1966 5hp johnson

Re: restoring a 1966 5hp johnson

btw the prop is 8x7-1/2.

 

[4.0l sahara]

Re: restoring a 1966 5hp johnson

Re: restoring a 1966 5hp johnson

Got the exhaust cover off. After taking heat,pb blaster and a impact dricer to the screws only one broke. Not bad for a salty outboard.

Now for getting the two broken bolts out. For the bigger one that holds on the power head I thought about cutting a grove in it and taking the impact driver to it. What do you think? For the one on the exhaust cover I don't have any ideas. Right now they are both soaking in pb blaster. I could always get a machine shop to get them out.

exhaust cover bolt

monting bolt.

The ones that snapped are the ones that whent into the water jacket. Well atleast the mounting bolt. Don't know about the other one.

 

[Solittle]

Re: restoring a 1966 5hp johnson

Re: restoring a 1966 5hp johnson

I would go the machine shop route. I would be afraid of screwing it up worse than it is and still not getting them out.

 

[4.0l sahara]

Re: restoring a 1966 5hp johnson

Re: restoring a 1966 5hp johnson

I mean I've drilled tapped and heli coiled before but it's a pain. The machine shop wouldn't charge that much anyway.

 

[Evinrude Boater]

Re: restoring a 1966 5hp johnson

Re: restoring a 1966 5hp johnson

Sahara,
Does yours have a screen in the water intake? Part No. 20 on the diagram.
Also, what did you hold the flywheel with? Don't tell me a flywheel holder.

 

[4.0l sahara]

Re: restoring a 1966 5hp johnson

Re: restoring a 1966 5hp johnson

I don't have that screen. For holding the fly wheel I had two freinds hold it. Didn't even think of a way to jam it.

 

[ezeke]

Re: restoring a 1966 5hp johnson

Re: restoring a 1966 5hp johnson

When do you plan to open your shop? I would like to make a small investment.

 

[4.0l sahara]

Re: restoring a 1966 5hp johnson

Re: restoring a 1966 5hp johnson

When do you plan to open your shop? I would like to make a small investment.

lol

 

[Evinrude Boater]

Re: restoring a 1966 5hp johnson

Re: restoring a 1966 5hp johnson

I don't have that screen.

Maybe that's why your water jacket was all plugged.

 

[4.0l sahara]

Re: restoring a 1966 5hp johnson

Re: restoring a 1966 5hp johnson

No they were full of corrosion and rust not mud or sand.

 

[Evinrude Boater]

Re: restoring a 1966 5hp johnson

Re: restoring a 1966 5hp johnson

Was the blockage just at the head or was it deep into the jacket?

 

[4.0l sahara]

Re: restoring a 1966 5hp johnson

Re: restoring a 1966 5hp johnson

When I first got it the water tube was full of corrosion. The head had alot of corrosion and the rest was just random spots in the water jacket.

 

[Evinrude Boater]

Re: restoring a 1966 5hp johnson

Re: restoring a 1966 5hp johnson

How far are you planning to go with this rebuild?

I ordered an impeller rebuild kit for mine. It's a bit confusing in that the rebuild kit is cheaper than the impeller alone.

I notice rust stains running down the exhaust shaft on my motor and wondered where it was coming from. I've never had rust coming out of my other motors. It seemed a bit odd.

 

[4.0l sahara]

Re: restoring a 1966 5hp johnson

Re: restoring a 1966 5hp johnson

As for the rebuild This what i'm doing

The power head has good compression and just normal wear on the cylinders.

Clean out water jackets
clean all the crap off the power head
carb rebuild
new gaskets for the intake/reeds
new head gasket
fix all broken bolts
new exhaust cover gasket
stripe all paint
new paint/clear
decals
points/condensors
spark plugs
water pump
lu seals
all the little seals and orings replaced
and may need to get a new prop shaft as the threads are screwed

 

[4.0l sahara]

Re: restoring a 1966 5hp johnson

Re: restoring a 1966 5hp johnson

Do you have a pic of the rust stains?