This Looks Bad... Is It?

brettagostini

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Jul 14, 2003
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77
I'm continuing to attempt to rebuild this '81 Evinrude 140. If you've never read one of my clueless threads; I'm a quivering virgin in this world of motor repair.

After taking the crankcase apart, I noticed this wear/damage in the crankcase cover.

I'm hoping to hear from you guys that this is normal wear and not to worry... but it looks bad to me. What do you think?
 

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guy74

Senior Chief Petty Officer
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Jul 12, 2007
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Re: This Looks Bad... Is It?

I don't see anything that I'd worry about, if you are worrying about the intake runner that is a little ruff. It was probably cast that way from the start. Everything I see in the picures looks ok, noting stands out as worn or damaged. I'm no expert on outboard motors, but I have a pretty good handle on most things mechanical. I'm pretty sure that opening is where the intake aircharge comes into the crankcase from the intake/ reed assm. Shouldn't be a critical point.
 

brettagostini

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Re: This Looks Bad... Is It?

Thanks, guy74.

I'm worried about the ruff metal edges... looks almost torn to my untrained eye. Here's a closer picture of what I'm talking about. This is the worst of it.
 

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guy74

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Re: This Looks Bad... Is It?

I've read your other posts, but I don't remember the details. Did the motor have a rod failure on that cylinder, or a loose rod cap. You are refering to the opening right in the middle of the picture, right? If so, I would just make sure that there were no pieces loose or about to break off, wouldn't want them to go though the engine. Unless I miss my guess, it will be alright to use. I think that piece is "married" to the rest of the crankcase, meaning it was bolted together then machined as a unique assembly. You can't just replace that piece, just like the main caps in any other engine.
 

flabum

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Feb 17, 2007
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Re: This Looks Bad... Is It?

I'm withy Guy, clean it up with a dremmel and let her rip
 

brettagostini

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Jul 14, 2003
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Re: This Looks Bad... Is It?

Nope, no rod failures or anything like that. That edge and a couple others just looked so jagged that I was worried something I didn't know about had gone wrong. Thanks for the input guys. I'll buff the rough spots smooth with a dremel and drive on with the mission.

Thanks again. I'll be back with more questions soon, I'm sure.
 

rudedude

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Aug 20, 2007
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Re: This Looks Bad... Is It?

That looks like a mess, motor isnt any good , you better just send it to me and I will get rid of it for you.:rolleyes:
 

flabum

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Feb 17, 2007
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567
Re: This Looks Bad... Is It?

That looks like a mess, motor isnt any good , you better just send it to me and I will get rid of it for you.:rolleyes:

Aww come on dude, he's nervous enough as it is...... next you will be telling him that red stuff won't come off.
 

rudedude

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Aug 20, 2007
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Re: This Looks Bad... Is It?

Yea, that red stuff is bad also. :D
 

reeldutch

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Feb 2, 2004
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1,340
Re: This Looks Bad... Is It?

looks good to me

however what you should check out is the crankcase mating surface, block mating surface, and check the straightness of it, block and crankcase.

before putting it back together clean all bolt holes so you can torqeu it down to the right spec.

make shure the crankshaft bearings fully seat in the dowel pin(s) or it will never seal propper and you will crack the bearings.
 

rudedude

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Aug 20, 2007
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Re: This Looks Bad... Is It?

I'am just messing with you, it should be fine but you could still send the motor :D:D:D:D:D:D
 

brettagostini

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Re: This Looks Bad... Is It?

The red stuff won't come off?? Damn!! And I've been trying to get it off with a hammer and chisel for a week. :D

I'm sending the block off to you rude dude. But I only had small boxes, so I had to hacksaw it into seven small pieces. Hope that's OK. ;)
 

ddennis

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Joined
Aug 15, 2006
Messages
351
Re: This Looks Bad... Is It?

I'm sending the block off to you rude dude. But I only had small boxes, so I had to hacksaw it into seven small pieces. Hope that's OK. ;)


Nothing a little JBweld wouldn't fix! LOL
 

Lakester

Chief Petty Officer
Joined
Nov 17, 2007
Messages
428
Re: This Looks Bad... Is It?

b'stini:

Good for YOU! :D such courage to tackle not just an engine repair, but... and outboard engine repair! :eek: LOL!! i hope the tech and advice here will guide u thru your journey. :)

btw, why did u take it apart?

if that ruff edge was mine, and if i had the files [i do; small round and smaller...course, med and fine...] i would hand dress the edges. i do like my dremel and use it oft. in fact i have a head bolt project coming up i think my dremel can help me with. but from my side of the shore... i would hand dress it.

good luck and look fwd to more progress reports. really enjoyed the pix... :)

regards

lakester :cool:
 

brettagostini

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Jul 14, 2003
Messages
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Re: This Looks Bad... Is It?

I took it apart for a series of reasons. The boat had been parked (outside, all year, in Pennsylvania) for seven years... used one summer.... parked for five years. Then when I tried to use it last summer, it would run, but VERY badly. Wouldn't even pull a single child on a wakeboard.

So, I checked the compression and found all the cylinders were way different. Also knew that it had never been winterized, so was sure the carbs needed complete cleaning.

Also, I figured that after such a harsh time period and bad performance there would be other issues. So far I've found a busted ring on one piston, so I know that that was a huge issue. Carbon everywhere. Also found what I'm pretty confident was a very leaky head gasket. I will be getting the cylinders mic'ed and gauged, and probably rebored.

And since I've gone this far, I figure I might as well spend the winter getting to know this engine inside and out. (I've never done anything even remotely mechanical before. I don't even like to change my own oil.)

So I'm off on this big adventure, with you folks to guide me.

Next summer.... Re-doing the interior!!
 

Lakester

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Joined
Nov 17, 2007
Messages
428
Re: This Looks Bad... Is It?

I took it apart for a series of reasons.

So, I checked the compression and found all the cylinders were way different.

Also, I figured that after such a harsh time period and bad performance there would be other issues. So far I've found a busted ring on one piston, so I know that that was a huge issue.

Also found what I'm pretty confident was a very leaky head gasket. I will be getting the cylinders mic'ed and gauged, and probably rebored.

And since I've gone this far, I figure I might as well spend the winter getting to know this engine inside and out. (I've never done anything even remotely mechanical before. I don't even like to change my own oil.)

So I'm off on this big adventure, with you folks to guide me.

Next summer.... Re-doing the interior!!

hello b'stini,

thanks for the feedback. :) so i am curious... when u did the compression test what was the reading on the bore sporting the broken piston ring? and the others, too? what were they?

did u see any bore scratches on the one with the broken ring?

what indications do u see or made u think u had a bad/leaking head gasket?

i am also getting to know my engine inside n out, [1971 85HP evinrude] got my oe outboard parts manual today, in fact. and thinking about pulling the heads. just because of 37 yr old head gaskets and despite good to better good compression... the clamp load may have subsided some over the yrs and could potentially be a failed water to bore leak... soon. :eek: i have the head's water passage plates removed and gaskets [finally cleaned 8 hrs 2 sides!!! :mad: ] cleaned and ready for fresh gaskets... ;) but i am tossing around pulling the heads, too.

well, unless the bores are really egg shaped and the piston's barrel shape gone or skirt grooving gone/worn off... fresh rings along with all the other stuff u will do... will do wonders to the engine. and they can be put in by urself and u can self hone it also with excellent results. no doubt the shop will love a rebore invoice, but a lot can be sed for doing it urself and saving the $$. even if my bores were weak and the pistons a bit worn, but engine ran good... i would just replace the rings, decarb the piston ring lands and hand hone the bores. in fact, once i learn more about the carbs, timing advance and all the side controls n parts... i plan to pop off the power head and do just that. maybe sev falls/winter time down the road.

for my 2-cents... be sure to install the piston rings with a ring expander! not by hand. if the shop will fit the pistons ask how they fit the rings. and u want no sharp edges at the ring gap ends. break them with a file.

pretty good work for a non-mechanical guy to catch a... Broken Piston Ring!!

mo pix and updates, please... :)

regards
lakester :cool:
 

watermellonI

Petty Officer 1st Class
Joined
Jun 23, 2007
Messages
224
Re: This Looks Bad... Is It?

Hey Brett,
Just wanted to add some encouragement, looks like your doin great, I finished putting a 3.0 together a couple weeks ago, my first rebuild, and for someone who doesn t even change their oil, your doin great, just stay steady and don t rush, and when you get her together don t let it scare the crap out of you when it starts!!!
 
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