2001 johnson rebuild questions

[bradw18]

im in the process of rebuilding a johnson 2001 90hp v4. long story short owner didnt know what the beeping sound was and why the boat was in "limp mode" as i call it so he kept going for another 30 mins with no oil. so far from what i can see the bottom of one of the piston skirts is damaged. im guessing ill need to get her bored. i dont trust any machine shop in this area and im located in henderson ky. they barley have enough knowledge to bore a small block chevy. this is my first outboard rebuild but im not new to engines or 2 strokes.

whats the average cost to get the engine bored. and shipped. and can i just bore one cylinder and buy one over size piston instead of all 4.

 

[Scurvy Knave]

Re: 2001 johnson rebuild questions

can't help you with the cost. But as far as only doing one cylinder, I would do all 4. If you're going through all that work, might as well do it all - then you won't have to worry about the other 3 suffering in the future from the damage done by the PO. How do the bearings look?

 

[bradw18]

Re: 2001 johnson rebuild questions

Havnt gotten that far yet. Iv ordered a repair manual. I was able to see the bottom skirt by looking threw we're the reeds go. I Agree with doing All cylinders. What's the diffrence in the 90 and 115? Just bore?

 

[Lightning1]

Re: 2001 johnson rebuild questions

Last boat motor I had bored they charged 35 per cylinder.
Prices vary a lot from shop to shop, and some do better jobs than others.
Try to find one with experience with boat motors, (or at least 2 stroke engines)
You say the piston skirt is damaged, Unless there is cylinder damage, or worn barrel shaped,
You wouldn't need to bore. Just hone and replace damaged piston(s)
I also agree with Scurvy that you should do all four.

 

[bob johnson]

Re: 2001 johnson rebuild questions

Lashelle Engine Restorers. 81802 crssroads ln, Freeport Ill 61032 I think!!!! the Phone is 815 821 3546...the guys name is Jim.... he knows how to do the flat bottom bores.... much different than the bores that go through to air!!!..you need special boring tolling and hones bob

 

[bradw18]

Re: 2001 johnson rebuild questions

Iv gotten all the bolts out of the crank case cover. Trying to see the crank. Iv also gotten flywheel and stator off and having a hard time getting the case to split. The bottom prys away from the block itself but act likes something's holding the 2 halfs togeather still. Any ideas? Don't want to pry to much infear of damaging the housings. The top of the pistons all look great so I hope the rings didn't break and really scar the bore I'm very close to finding out will post pics soon

 

[bradw18]

Re: 2001 johnson rebuild questions

 

[bradw18]

Re: 2001 johnson rebuild questions

She's gotta be bored. Other 3 pistons look great no scoring of any kind. One would think if ran out of oil all cylinders would look like that.

 

[Faztbullet]

Re: 2001 johnson rebuild questions

any machine shop in this area and im located in henderson ky.

PM me.....

What's the diffrence in the 90 and 115? Just bore?

Exhaust port height and carbs......

 

[bradw18]

Re: 2001 johnson rebuild questions

Next problem I'm having is splitting the power head from the lower unit. I guess I worked backwards and instead of splitting the power head from the lower unit first I tore motor Down with out splitting them. I removed all the bolts between the lower unit and power head but still nothing. Any advice?

 

[bradw18]

Re: 2001 johnson rebuild questions

Finally got my manual in and crank case split from the lower unit. Been reading the manual an Iv been wondering if I need to buy any special tools. Looking at alignment fixture p/n 396749 for the rod caps. The caps are a lot like ls1 rod caps that are casted as one piece and then broke. They only line up one way. And so far cheapest place Iv found a bearing kit is 500. That's for rod bolts inner and outer crank bearings and the outer bearing lining. My outer bearing cases don't have any groove in them. Would I be ok with just buying the roller bearing part with out the outter casing? Has anybody done this before?

 

[Scurvy Knave]

Re: 2001 johnson rebuild questions

As an aside, while you have it apart, consider what might have cause the one cylinder to be damaged. Might as well fix that now rather than fix the cylinder and have the same problem again. If it ran out of oil, you would expect damage in all cylinders. Could it have overheated in the one cylinder? are there any revisions necessary to the cooling system?

Regarding your question, what is the added cost for the new casings? Is it worth saving? Do you have a way to check the casing thickness and eccentricity? Old wine in new ewers and new wine in old ewers and what not...

 

[bradw18]

Re: 2001 johnson rebuild questions

The problem was Running her out of oil as the slow alarm was on and the owner continued to idle to the docks. ( owner is my gpa). I have calipers and can get a set of bore gauges. With them being roller bearings I'm thinkin the possibility for ware is minimal not like a old school bearing that runs out of oil and start showing brass very quickly. I'm defentally going to replace all the needle bearings and cage bearings just didn't know if I needed to break down and buy the outer casings also as they all look great. I think it also weird that only one cylinder Is scared an shows signes of ware. I'm shipping her to fazt for pressure testing and then boring. She's also getting new water pump and premix from now on. The boat she was on was a 22ft Bennington pontoon boat. Not abused or held at wide open for very long at all owner is a 64 year old and he has Owned it since 2001.