1976 Johnson 25RL76E Metal Chips In Cylinder Head.

[Beebe4]

Hello all,
The motor has been running great until last Saturday. Started it up took off, went to WOT and the engine died. The pull card would not pull at all. Great a frozen engine I thought. I took the pull cord assy. off and it worked fine. I tried to move flywheel, and it wouldn't budge. Put a wrench on it and freed it. The pistons where moving up and down, however the flywheel would stick at times, until finally it froze again. I assumed a bearing, so I started pulling it apart. Took the cylinder head off and found aluminum metal chips. (see Pic). The cylinder bores are smooth as silk. What on earth is going on?
Thanks,
Guys

 

[AlTn]

pull the powerhead and disassemble...keep the conrod bearing halves and needle bearings together along with the wrist pin bearings for each cylinder.. separate and apart from the other cylinder...you could have ingested part of a reed valve, a broken ring, bearing, etc. ...something obviously ain't where it oughta be...hope for the best but you'll have to tear it down to inspect/repair...an OMC Factory Manual will be of great benefit

 

[Beebe4]

Thanks. After some research Iv've seen that I should drop the lower unit and see if the crank shaft turns. Should I try that?

 

[F_R]

Thanks. After some research Iv've seen that I should drop the lower unit and see if the crank shaft turns. Should I try that?

Obviously, the lower unit has nothing at all to do with the problem. A piece of some busted object was banging around in the cylinder. You will have to dig deeper to find out what that busted object is. My guess is a piston ring. But don't go by that, it could be one of several other items.

 

[Beebe4]

Oh BTW. Im 99.9% sure the chips are aluminum. What could that be? Rings aren't made from aluminum are they?

 

[gm280]

IF you are positive it isn't a ring (that's what I am thinking as well) then look at the carb and see if anything is missing from the carb. Either way, you are going to have to disassembly the engine now and inspect everything to see what it is... You may get really lucky and not have bores messed up and can hone the cylinders and re-ring it while you have it down. Take pictures and post them here. I am interesting for sure...

 

[Beebe4]

IF you are positive it isn't a ring (that's what I am thinking as well) then look at the carb and see if anything is missing from the carb. Either way, you are going to have to disassembly the engine now and inspect everything to see what it is... You may get really lucky and not have bores messed up and can hone the cylinders and re-ring it while you have it down. Take pictures and post them here. I am interesting for sure...

Thanks. The bores are very smooth. It may be a ring, but like I said I'm pretty sure its aluminum chips. I will post pics.

 

[Chinewalker]

Could be a broken piston skirt or ring land (between the rings). In any case, a full teardown is in order.

 

[F_R]

I think you are going to find that piston totally destroyed. But remove the bypass cover from the side of the cylinder and you can peer in for a looksee. If nothing else, to convince yourself that it is busted up.

 

[Beebe4]

No Title

I think you are going to find that piston totally destroyed. But remove the bypass cover from the side of the cylinder and you can peer in for a looksee. If nothing else, to convince yourself that it is busted up.

Great you may be right. This is the top view of the cylinder it's smooth. I have more pics but cant upload them. Ill start a new thread.