Re: Johnson,Evinrude V4 90-140HP
DHadley is the crossflow guru here. He described some of the differences for me a couple years back when I was in a similar situation. There are several different crankshafts that can be used, but there are conditions. Some use different bottom main seals, so you have to keep the correct bottom main bearing carrier/seal assembly with the crankshaft in order to use them, .ie if you use a 1993 crankshaft, use a 1993 bottom seal/bearing.
Not a whole lot of difference in the heads - I was told they could interchange with little effect. Key is to keep them matched - casting numbers one off from each other.
The extra horsepower comes from bigger carbs, bigger ports, and bigger exhaust. 140s have what is referred to as a "bubble back" exhaust, which is essentially a tuned expansion chamber that extends beyond the normal flat back exhaust plate.
There is a lot of mixing and matching that can be done with the crossflows you mention - some is trial and error - some can be found through some board searches here on iboats. Lots of folks trying to get their 85s and 90s to go like 115s and 140s...
- Scott