Re: 1988 Johnson 90hp got stuck in the mud
Remove cylinder heads, carefully clean/resurface the sealing areas of the heads and block (crankcase). Replace the water deflectors as instructed below.
Install new head gaskets and torque the bolts down to 18 to 20 foot pounds in the following sequence:
9....10
5.....6
1.....2
4.....3
8.....7
Nearly all of the rest of the powerhead bolts will be loose due to the extreme heat.... tighten all of them as needed.
Install new Champion QL77JC4 spark plugs, gapped to .040 .
(Water Deflectors)
(J. Reeves)
Water deflectors are actually lengths of 3/8" outside diameter rubber hose, installed between the top cylinder and any cylinder beneath it, and also between the bottom cylinder and the block. The purpose of the deflectors is to have the water follow a definite path around the cylinder walls. Unfortunately the deflectors between the cylinders will at times swell sideways due to either a previous bad overheating problem, or simply due to age and salt corrosion. This causes a water flow restriction which usually allows the water to cool sufficently at low rpms but not at the higher rpms.
This hose material can be purchased reasonably at any automotive parts type store if you care to make your own, or you can purchase individual deflectors at any Evinrude/Johnson dealership at a somewhat higher cost.
Removing and installing them can be a hassle at times, but not always. I use a sharply pointed scribe with about 1/4" of the tip bent at a right angle whereas I can reach in, jab the tip sideways into the rubber, then yank it out. It's necessary to clean the seating surfaces where the ruber contacts the block with a small rat tail file to eliminate salt deposits etc. When installing the new rubber deflector, coat the deflector and the metal surfaces with WD40 which will act as lubrication to allow it to go in as easily as possible.
Make sure that you insert something into that deflector area before cutting and installing the deflectors if you make your own so that you will be certain that they are the right length and also that they will be seated properly. Usually a very small amount will be left extending about the block sealing area..... simply cut the excess off with a single edge razor blade.
Drop the lower unit and have a complete water pump kit (everything) installed. Make sure that you do not turn the shift rod as its height adjustmment is extremely critical.
Your overheat warning horn should have come on befor the engine was hot enough to do any damage. If this warning horn did not sound..... correct that problem before running the engine again.
