1978 Johnson 115 (115ETL78C) cylinder sleeve

[Deuce24]

is it possible to resleeve this motor? Original plan was to pull defective sleeve and replace with new. Now that I have the piston removed and can get a better look it looks as though the current sleeve is keyed. I assume this is so the sleeve doesn’t slip or rotate. So I would also assume since it’s keyed it cannot be removed and new sleeve put back in? What are my options with this motor. Pics attached you can see what I am saying as far as “keyed” when you look at the edge of the ports.

 

[racerone]

Correct those sleeves do not come out !-----What size is the bore now ?-----What happened to the piston / rings ?------Lots of options with O/S pistons and rings.----Your location ?

 

[Deuce24]

I have not mic’d the current bore size, I will do that this evening. Dropped cylinder heading back to dock a few months ago, went through electrical system, which checked out. After doing a compression test I discovered this cylinder was approximately 20% lower than the other 3, they were 120, 120, and 117. This one was 103. You can also see the scoring on this cylinder. I bought the boat used and it ran great for a couple months until this happened. I am located in northern ky 15 miles south of Cincinnati. Thanks for the response!

 

[racerone]

Just more proof that a compression test is to be done FIRST in trouble shooting.-----I do not have enuff fingers and toes to count how many times I have seen this failure.-----You need 4 new pistons along with rings.

 

[Faztbullet]

.020 should clean that up....

 

[keefallan]

Agree. You don't need a sleeve, just have the cylinders bored out, 4 new pistons........new engine. Go thru the carbs to be safe..........easy rebuild too.

 

[keefallan]

You can get pistons up to .040 for that engine

 

[racerone]

Actually you can get up to 0.064 " O/S for that.--------Not that I would recommend to go that big.