Omc 115 Turbojet stripped down and starting the rebuild

[Abomb27]

Re: Omc 115 Turbojet stripped down and starting the rebuild

First time doing them, first they would stick to my finger, then I was trying to put the wrist pin through the washer then through the rod bearings, and I kept knocking them loose. Then I figured out to go through the washer and rod bearing in one piece, and slide the last washer in. If I had a second motor to build, probably could do it in half the time, with all the things you pick up from the first one. Always learning.

 

[racerone]

Re: Omc 115 Turbojet stripped down and starting the rebuild

Did you use " needle bearing assembly " grease ?----Are there lube holes in the rods at the small end and are they going to be on the top side when in installed.

 

[Abomb27]

Re: Omc 115 Turbojet stripped down and starting the rebuild

I did use needle bearing grease, and I do have the oil holes facing up. I had to check the position of the piston a few times, but im confident its facing the right way. I had grease coming out of the oil hole, after I put the rod and piston together. I wiped it and squirt some two stroke oil in there. I oiled everything pistons, cylinder bearings. So far so good. Im waiting for my loctite 518 flange seal to come, so I can put the two halves back together, after a little more work? Is the 518 good stuff?

 

[boobie]

Re: Omc 115 Turbojet stripped down and starting the rebuild

It probably is. I always used Gel-Seal II. Use the primer if you want it to set up faster.

 

[Abomb27]

Re: Omc 115 Turbojet stripped down and starting the rebuild

Thanks boobie, I bought both. I have all the pistons in and the heads on. Tomorrow I am going to tackle getting the crank back in.

 

[Abomb27]

Re: Omc 115 Turbojet stripped down and starting the rebuild

Quick question. Cleaning the upper and lower crankase heads. The guy before me put some kind of rubbery sealant on them. I cleaned it all off, I put new orings and new seals. My manual states to put gasket sealing compound on the outside diameter of the heads. I am going to follow the manual, but my manual is 18 years old. So what is the correct way?

 

[racerone]

Re: Omc 115 Turbojet stripped down and starting the rebuild

A mechanic who knows and understands outboard motors rarely uses lots of sealants.-----------------Reason ?----------Take a look between those o-rings on the cranckcase heads.-----You will see a hole drilled.--------Do not take any chance of plugging that hole.----Has to do with recirc system for oil !!!!

 

[Abomb27]

Re: Omc 115 Turbojet stripped down and starting the rebuild

I had a feeling the sealant was wrong. I made sure to clean that hole out, and I squirt some oil in there also. Thanks. So I got the crank in, pisotn rods bolted on. Just waiting for my flange sealant, I ordered it online.

 

[racerone]

Re: Omc 115 Turbojet stripped down and starting the rebuild

Simple question ----How did you torque the connecting rod cap screws and how long did it take to torque those 8 screws ??

 

[Abomb27]

Re: Omc 115 Turbojet stripped down and starting the rebuild

I used my 3/8" torque drive wrench with a 1/4" adapter and a 5/16" deep 12 pt. Socket. I brought the rod and halfbearing up to the crank one at a time and finger tightened the rod bolts using just the socket. I did all four that way. Then I went back checked the alignment on the two halves, I moved them whichever way they needed to line up perfect then tightned them a little with the wrench, I did all four. Then I went over one more time with a small screwdriver, checked all sides for a bump, when they were smooth I snugged them up. I always tightned both sides in small increments alternating back and forth. Finally using my torque wrench I tightned one side at a time 1/4 turn till I had them torqued to 32 ft/lbs. And I used new bolts.

 

[Abomb27]

Re: Omc 115 Turbojet stripped down and starting the rebuild

Forgot.......probably took me about 1/2 hour, I was wiping down the bearings and putting fresh oil on them. I was trying to take my time and get it right.

 

[boobie]

Re: Omc 115 Turbojet stripped down and starting the rebuild

A sharp lead pencil also works good for checking rod alignment.

 

[Abomb27]

Re: Omc 115 Turbojet stripped down and starting the rebuild

Thanks boobie. I will double check it with a pencil. If still waiting for my flange sealant. So I cant finish putting it together yet.

 

[Abomb27]

Re: Omc 115 Turbojet stripped down and starting the rebuild

Finally my flange seal came in. I put the crankase halves back together, and put the intake on. I have a few more bolt ons, like exhaust and by pass covers. Then I am going to put a fresh coat of black paint on it.

 

[Abomb27]

Re: Omc 115 Turbojet stripped down and starting the rebuild

I know its been a while. But here's my update. Motor is back together with a shiny coat of gloss black heat paint. I have to put the solenoid and starter on. Rebuild the carbs, mount them. Then bolt the motor onto the big plate, not sure of the name, maybe muffler assembly. Install fuel pump, then back into the boat. I bought new stainless thermostats, I checked them in hot water to make sure they open.

 

[Abomb27]

Re: Omc 115 Turbojet stripped down and starting the rebuild

Now with the carb rebuild. I bought a few different jets. I have the boisen power reads, so I went two sizes smaller with the air, like they recommend so the motor doesnt run lean. Also my boat is a 1996, 1997 model has an identical engine and carbs but the high speed jet is one size bigger then mine. So I figured it is an improvement so I got them for mine. Does anyone see that as a problem, or not much of a difference at all?

 

[Abomb27]

Put the motor in the boat today. Attached all hoses, electric, and fuel lines. After I figured out how to prime the fuel and oil lines, it fired right up and purred like a kitten. The only issue is there was a little water pooling on top the engine. I have to figure out where its coming from. Thanks everyone for all the help. Im very happy that it was a succes. This was my first engine rebuild, and I am damn proud of the results.

 

[Abomb27]

Is it possibly for water to be coming out under the rectifier? That's where it looks like it's leaking from.

 

[racerone]

Yes it is a watercooled rectifier / regulator , possibly the gasket is leaking.

 

[Abomb27]

Thanks racerone you were right. Gasket leaking. The rectifier bolts were tight, then I tightened them a little more,and I could wiggle the gasket in the starboard stern side corner. I pulled the rectifier it was clean and so was the block and the gasket is new. So I put silicone on the block and on the rectifier,put the gasket in between and tightened it down. I got a nice ooze of silicone all the way around. Hopefully that works.