Advice on rebuild needed: 2.5 hp powerhead

[Aquatical]

My little kicker motor seized, 1988 2.5 HP Johnson. Took it apart yesterday and found that the needle bearing liner in many pieces and a loose, bent rod cap for the lower cylinder. Seems to me like a bolt came loose off the rod cap. The piston walls seem fine. The piston itself sustained a couple of teeth-like gashes below the rings, see the picture. Will those affect anything?

Also, there was wear along the base of the crankcase, and a divot. Is that divot an issue? All I think I need is a new bearing liner and rod cap, but checked prices online and they want $50 for a complete rod set, they do not sell just rod caps. And another $50 for a liner/needle bearing assembly. I cannot just buy the liner! Guys, should I rebuild? Or buy another used motor on Craigslist for around $250-$300

 

[wilde1j]

Re: Advice on rebuild needed: 2.5 hp powerhead

There are a lot of good reasons you cannot buy part of a rod or bearing assembly. The cap and the rod are made as one piece, then fractured... it can only be correctly assembled one way. What makes you think the bearing needles are OK after the shell fractured?

You need to have someone who knows measure both cylinder bores to check for roundness and bore. This will determine whether the holes need to be bored. Then decide what you want to do. You may be in for one or two pistons and ring sets. If you plan on doing the work, get an OEM shop manual, since your questions certainly reflect inexperience.

You should also determine the cause of the failure, if you don't want it to recur. If it was a bolt from the rod cap, someone had the motor apart and didn't torque the cap screws properly.

 

[Aquatical]

Re: Advice on rebuild needed: 2.5 hp powerhead

Good advice, probably not worth the time involved or money to rebuild. Rather keep it around for spare parts- and buy another used one.