Crankcase Hole in my 1997 200 Evinrude

[clifton63]

Hi,
First post here, unfortunately it is a depressing one. I recently bought a used boath with a 1997 Evinrude 200 Ocean Pro. It has always been hard to start but once it starts it runs great. After a weekend of fishing, I noticed the engine running a little "bogged down" (like the plugs were fouled). I put it on the trailer and went home. Now it would not start at all. I pulled the carb air cover off and noticed a piece of metal that was inside on the intake. I thought that was odd and it must have come from somewhere on the engine. I looked over the engine real good and discovered a Quarter sized hole in the crankcase about 3 inched above the fuel pump. I could actually see the connecting rod through the hole. I don't have a lot of money to go buy another. What can be done to repair this hole? (assuming that the connecting rod is good and a nut did not come off). Is there a product out there that can repair like JB weld or something? PLEASE HELP!!

 

[oldcatamount]

Re: Crankcase Hole in my 1997 200 Evinrude

You got to find out what made the hole first, but it can be welded. I don't think JB weld would work as the hole is too large and there is pressure on the inside.

 

[Chris1956]

Re: Crankcase Hole in my 1997 200 Evinrude

I will guess you will need to pull the crankcase cover and see what caused the hole. Maybe a missing piece of piston skirt?

The hole does sound a bit large to epoxy(Marine-Tex), unless you epoxy some metal on the outside, to overlap the hole.

 

[clifton63]

Re: Crankcase Hole in my 1997 200 Evinrude

Update,
I found the cause. The hole is right where the side of the connecting rod (where the seam is) sweeps by the crankcase. The connecting rod looks fine and I jiggled the flywheel and there was some minimal play where this rod connects to the crank. I suspect that there must have been some play somewhere in the crank or rod, enough to where the rod side actually hit the crankcase. The hole is exactly the same size as the connecting rod thickness so this is what happened. Has anyone heard of bearing slop enough to cause this? How else could this have happened? (This rod is the top cylinder on the left side as you are looking at the backside of the engine). I will say that when I put the boat on the trailer, I drove it on pretty hard and the engine died when I got it up on the trailer. That was the last time it ran. I suspect that I may have torqued the motor enough to cause the rod to slap the side of the case. Any ideas, total rebuild in order?

 

[Dhadley]

Re: Crankcase Hole in my 1997 200 Evinrude

Unfortunately there's no such thing as "minimal acceptable play" when talking about a rod bearing. We'll need to get it aprt at this point, let us know what you find.

 

[clifton63]

Re: Crankcase Hole in my 1997 200 Evinrude

In pricing a used crankcase and rebuild kit, it probably wont be worth rebuilding. I can probably pick up a used EFI for a grand or so more and part this one out. I was hoping for a cheap fix. Is it normal for the rod bearing cap to run that close to the crankcase wall? Looks like about 1/8" clearance. Is it hard to rebuild one of these outboards with home tools? I have rebuilt auto engines and did a honda goldwing engine and harley engine.

 

[wilde1j]

Re: Crankcase Hole in my 1997 200 Evinrude

An 1/8" clearance is plenty. If the rod moved that much or even a lot less, you have a major problem(s) inside. If you have a torque wrench or two, a flywheel puller and a flywheel holder, you don't need much more that most home mechanics would have. An OEM shop manual is very useful as well.

 

[1946Zephyr]

Re: Crankcase Hole in my 1997 200 Evinrude

If you can see the rod cap through the hole, check and see if the rod bolts are tight. It sounds like one has backed out and punched the hole out. Also, you might try to look inside the hole and see if the pistons are complete, meaning no chunks have broke off.

 

[F_R]

Re: Crankcase Hole in my 1997 200 Evinrude

It is totally impossible for the rod to contact the case unless it is loose. Or some other foreign object got between the rod and case. Whatever, a teardown and inspection is necessary.

 

[Silvertip]

Re: Crankcase Hole in my 1997 200 Evinrude

An engine is an engine and "home tools" means different things to different people. But if you have an above average set of tools you can work on this motor. If you have the piece from the hole, save it. Remove the power head, disassemble it and examine the bearing journal and rod big end for damage. Mic the journal for wear and check surface condition. If it is within spec and not scored it is ok to use. If not, its new crank or rebuild time. Something on the crank, bearings, rod or piston caused the damage. Since the block is disassembled, bolt the two halves together and any good welder can weld the slug back into the hole without warping the block. Do not attempt to weld on just the damaged case as it will likely warp. It is odd that the broken piece was found in the intake which unless I misunderstood that to mean it got past the reed valves. That would mean those are damaged as well.

 

[clifton63]

Re: Crankcase Hole in my 1997 200 Evinrude

The broken piece happened to fly off and landed inside that plastic carb cover in one of the rectangular intakes. I took the carb cover off and heard something rattling and when I turned it upside down that piece of metal fell out and I said "oh Sh**, that had to come from somewhere. The rod had have hit it pretty hard for it to fly off like that. Strange the rod looks fine when looking through the hole and feeling it. I must have been a piece of metal getting in between the rod and the case wall. As someone suggested, I would place my bets on a piece of piston skirt. At this point, I have nothing to lose by opening her up to see what is going on and I can only buy what is needed and make the decision to rebuild or part it out. I might do the welding thing or just buy a used one off ebay. Looks like I have a winter project now!

 

[daselbee]

Re: Crankcase Hole in my 1997 200 Evinrude

Would you PLEASE do me a favor?
Few posters here reply with the end results.

PLEASE, when you get that hole welded, post back on how well it worked for you.

I really want to know, because I have an engine with a hole in #2 crankcase, and I have been told so many different stories about welding it...

Most ppl say you cannot weld cast aluminum effectively. I want to know.

 

[SparkieBoat]

Re: Crankcase Hole in my 1997 200 Evinrude

I graduated from tech school for welding and metallurgy, cast can be successfully welded or brazed, in order to weld the cast iron must be pre heated and then welded with nickel rods in short burst, maybe 1/2 inch at the time, you then relieve stress by hitting it with the round end of a ball peen hammer, and letting it cool as slowly as possible, sometimes you still get stress cracks. you can also drill small holes at each end of the weld to relieve stress, then weld up hole after it has cooled and been preheated again. slow cooling is the trick. Brazing is another option and will hold a fair amount of pressure and will not get the iron hot enough to stress crack, considering the quality of iron I have seen in OMC motors I would recommend the brazing option. If you have a large hole, place a piece of steel over the hole then braze it into place.

 

[wilde1j]

Re: Crankcase Hole in my 1997 200 Evinrude

Yeh, except the block is aluminum, not CI.

 

[SparkieBoat]

Re: Crankcase Hole in my 1997 200 Evinrude

cast aluminum is much easier to weld..you need access to a TIG welder, and someone who knows how to use it. should not be a problem. just make sure you clean the aluminum very good with a stainless steel wire brush before welding

 

[Silvertip]

Re: Crankcase Hole in my 1997 200 Evinrude

I have done this to a Johnson 3 cylinder and the outcome was fine. It all depends on where the hole is and who is doing the welding. This is all moot however if the block is junk because a piece of metal has been dancing around inside it and the block is simply beat to death.

 

[clifton63]

Re: Crankcase Hole in my 1997 200 Evinrude

Yes metal has been dancing around. this evening I found the "bullet" laying down in the lower cowl. It was a piece of the piston skirt (bottom edge of skirt about 3/8" in diameter). I guess it got between the case and the rod end and it came out with the piece of the case wall when the rod sandwiched it. Anyway mystery solved. time to tear it apart. I am still on the fence though about rebuilding it or getting a used EFI. I am seeing them for around $2k to $3k. and I figure I have about $700 in parts. (not including the nice SS prop I have). I might be better off going that route. Still have to tear it apart in order to part it.

 

[Jayrock]

Re: Crankcase Hole in my 1997 200 Evinrude

I have a 1996 90deg v-6 for 200,225 crankcase Ill prety much give ya. it needs two holes sleeved, but all else is good. I can get 100 bucks for it at the scrap yard. it yours for that price if ya want it. The taper pin even comes out like it should... I live in southern Ca if it helps ya.

 

[clifton63]

Re: Crankcase Hole in my 1997 200 Evinrude

thanks, I might work with you on that. Not sure what you mean that it needs 2 holes sleeved and how much does that cost?. Sorry.

 

[daselbee]

Re: Crankcase Hole in my 1997 200 Evinrude

Jayrock,

How are you getting a hundred bucks for this used block?
Scrap cast aluminum prices here in FL are 0.35/lb. The block weighs about 45 pounds, so it comes to roughly $16.00 to sell here.

And, most scrap metal yards here will not give the 0.35/lb price, because it still has the steel sleeves in it. They only give aluminum price for PURE aluminum metal pieces, not mixed.

How does it work in So.Cal?