Update on my 90HP evinrude im trying to get to run...

[KillerJello]

If you havent seen the other post, I got a 90 hp 1964 evinrude with electric shift, was told there was only wiring problems and the engine ran last time it was out... i got it for free so i bought a service manual and figured i would do an overhaul on it since it wont turn over at all. The powerhead has no signs of any trouble...<br /><br />BUT.... heres the update.... <br /><br />I pulled the lower unit off tonight to find about 500 acorns and other nuts jam packed in the housing above the lower unit, along with a mouse nest. Im thinking this may be half the problem, as i had to take a screwdriver to pry the junk out. the prop spun freely as it is in neutral, but the motor wouldnt turn. I havent tryed turning it over again, since i cant get the lower unit completely off yet because the release on the motor mount is messed up and wont let me tilt the motor, and my engine stand isnt tall enough. Im gonna work on that problem tomorrow, along with posting pictures of the mess inside this outboard just thought i would update you guys on it, and so far the rebuild is going good, no MAJOR problems yet, just minor stuff like mice nests and everything...

 

[OBJ]

Re: Update on my 90HP evinrude im trying to get to run...

Hi Killer....<br /><br />Have run into mice nest myself on occasion. They like to get in under the hood where there are lots of wires to chew up. LOL. Yeah. Keep us posted on your progress and if your having any problems.

 

[KillerJello]

Re: Update on my 90HP evinrude im trying to get to run...

http://community.webshots.com/album/93958301SRtCMW?954 <br /><br />theres the pictures i promised

 

[Solittle]

Re: Update on my 90HP evinrude im trying to get to run...

Never seen a mess like that - - <br /><br />Anyway when you get the lower unit off tilt the motor up and take the plugs out. Squirt some Marvel Mystery oil into each cly and let set for a day or so. Then take a socket wrench or breaker bar with a socket on the large nut on top of the crankshaft - give it a wrap. That should free your motor.

 

[KillerJello]

Re: Update on my 90HP evinrude im trying to get to run...

I already have the motor torn completely apart with the powerhead on the workbech... trying to figure out how to get the two centering pins out of the crankcase halves.... the manual says to use a center punch tapping it towards the intake, yet the way the block is designed it is impossible to get a punch in there....<br /><br />I tried spinning the motor with the lower unit off, and still nothing at all... i just cant figure it out, hopefully its something simple... the cylinders look perfect, no scoring or anything, and the rods from what i can see look brand new. I just hope its something just binding up inside thats easily fixable.<br /><br />As for the lower unit, after cleaning out that mess, it spins freely, and easily, so does the prop shaft. it is in neutral since i dont have any way to put it in drive right now. I did notice that it was extremely low on lube in the lower end, but it has been sitting for a few years. i filled it up and spun it about 150 revolutions, to get some oil worked in there the best i can. not too worried about the water pump, its getting rebuilt once i get the motor spinning.<br /><br />any tips on how to get those pins out though? once i get the block split, i think i can figure out whats wrong with the motor.

 

[SeaMasterZ@aol.com]

Re: Update on my 90HP evinrude im trying to get to run...

Joe Reeves to the Rescue! where is ya Joe?

 

[wilde1j]

Re: Update on my 90HP evinrude im trying to get to run...

Those pins are locating pins and there is usually no reason to remove them. They don't interfere with anything.<br /><br />In assume you used OMC Type C gear oil in the lower unit. The electric shift motors use a different gear oil from other motors.<br /><br />I don't think there was a need to completely disassemble the PH, but I would guess you'll probably find that the piston rings are rusted and locked up in the cylinder bores or a main bearing has failed and locked up.

 

[KillerJello]

Re: Update on my 90HP evinrude im trying to get to run...

I got it apart... I can wiggle the crank and the bearings look perfect, the motor looks like its been recently rebuilt, and has very low hours on it, thats how good it looks inside, however the crank will not spin, so it appears as if a piston is stuck, which leads me to my next problem... I cant get to the rod end cap bolts on two of the rods, one bolt per rod, the two middle roads i can get fine, its the top and bottom ones i cant. <br /><br />From what i can see of the pistons through the intake holes, there is no scoring on them. <br /><br />So now i need to figure out how to get those two end caps off, and then figure how to get the piston out if its stuck without damaging the block too much. <br /><br />I put the correct oil that the shop manual says for the electromatic shift.<br /><br />Anyways, if you guys could give me a tip or too for this problem im having, i would greatly appreciate it.<br /><br />Thanks,<br />Jason

 

[R.Johnson]

Re: Update on my 90HP evinrude im trying to get to run...

I take it that at this point have the heads off. If so, take a section of wood, such as a 2"x2" to put against the piston, and give it a sharp rap with a hammer to break the rings free.

 

[wilde1j]

Re: Update on my 90HP evinrude im trying to get to run...

I would try positioning the ccase half with the piston tops up and shoot some ATF or light oil along the cylinder walls and let the mess sit for a while. Then try tapping the piston tops with a rubber or leather mallet. You're likely in for new rings and a light honing of the cylinders if they mike OK for std rings. I would be inclined to leave the wrist pins installed.

 

[KillerJello]

Re: Update on my 90HP evinrude im trying to get to run...

Ill try that guys, thanks for the tips.... Ill keep you all updated on it. This is my first outboard ive worked on, and so far its going good (havent lost any fingers yet ) <br /><br />I have some pics of the block split in two that i will post later on today.

 

[KillerJello]

Re: Update on my 90HP evinrude im trying to get to run...

I was beating on the pistons with a 2X2 as told, and got three out of four of them to move, the other one is stuck pretty good. Im gonna pull the crank and other three pistons, and then concentrate on getting the 4th out of the block... through the exhaust ports i can see some minor scoring, but nothing bad, especially considering how old the motor is... once i get the piston out, i will go from there.<br /><br />On average, how much will it cost me for a new piston? I have all the equipment to recondition the block myself, though i would appreciate tips, as i have only done work on car, atv, snowmobile, and PWC engines before, though i do find this motor to be pretty similar in operation to a jet ski motor.<br /><br />Once again, thanks for all the help so far, Its a learning experience for me.

 

[Hooty]

Re: Update on my 90HP evinrude im trying to get to run...

When trying to unstick those thangs, use a mixture of 5 or 6 parts Marvel Mystery Oil to 1 part of Liquid Wrench.<br /><br />c/6<br />Hooty

 

[KillerJello]

Re: Update on my 90HP evinrude im trying to get to run...

Got 3 out of 4 out plus the crank, the 4th wont budge at all.... tried soaking it in the heated parts cleaner, tried heating it up with a torch, tried the mystery oil, exerything and still wont budge... the rest moved very freely. im hoping its just stuck.... anyone else got any ideas? the cylinders look perfect so far, they still got the crosshatches from honing from last time it was rebuilt. the bearings and crank look perfect too, no signs of the motor freezing up, so i hope its just stuck from sitting a few years...

 

[ezeke]

Re: Update on my 90HP evinrude im trying to get to run...

Careful now, the ring could be caught on a port.

 

[KillerJello]

Re: Update on my 90HP evinrude im trying to get to run...

nope the piston is a TDC it wont move either way... the rings are above the ports (i can see in the bypass cover)<br /><br /> it has me stumped how it can be so stuck...

 

[ezeke]

Re: Update on my 90HP evinrude im trying to get to run...

Don't know if it will help, but the original standard piston in the OMC parts manual was 380569. The .020 OS was 378814, and .040 OS was 378815.<br /><br />In the same order, the rings were:380110, 380111, and 380112.<br /><br />Maybe someone here will find a set they can't use and let you know.

 

[ezeke]

Re: Update on my 90HP evinrude im trying to get to run...

If the rods are free, have you tried to turn the piston?

 

[KillerJello]

Re: Update on my 90HP evinrude im trying to get to run...

yep, tried turning the piston, wont budge....<br /><br />that piston from what i can see through the intake holes in the side of the cylinder has some scoring, but not too bad... that piston is definitely being replaced though, as i doubt it will come out without more damage... I have the block soaking in parts cleaner overnight, hopefully it will help un-stick it.... ill let you guys know tomorrow, along with some pics of the progress so far...