Blown cyl on o3' 6hp Tohatsu. Fixable?

[Wee Hooker]

I've come into a 03' 4 stroke 6hp Tohatsu with a snapped connecting rod and hole in the cyl assembly . ( Right by oil filler cap where end of rod hit it.) The motor is in awsome shape, other than this major fault. Camshaft turns freely and doesn't seem to be gauled/damaged from the rod failure. Piston moves in cyl Ok when pushed too.
I'm pretty handy and that this motor is otherwise WAY to clean/nice to scrap. So, I'm thinking I need a new connecting rod+ cyl assy (pn# 3R1B01100-4 and 3H6-00040-0) and set of rings to put this back togeather ( assuming the hole in the existing cyl assy can't be patched.) So, how much am I looking at in parts to get this thing going again or should I just give up now and parts the motor out?

 

[Sea Rider]

Re: Blown cyl on o3' 6hp Tohatsu. Fixable?

You cannot patch a internal broken cylinder, a machine shop can place a false new standard cylinder, or buy a new complete crank case.

Happy Boating

 

[pvanv]

Re: Blown cyl on o3' 6hp Tohatsu. Fixable?

Hold on there. Better check everything over -- very well -- before dumping too much money into this motor. You will need to completely disassemble everything, get out your micrometers, telescoping gauges, and dial indicators, and do a complete inspection of all the bits. When a rod blows, it can take out a lot of other parts with it. Here's what you might be looking at:

Odds are you can't repair the cylinder/crankcase, so you would need a new one.
3R1B011004 CYLINDER, 4A2/5A2/6A2, NEW STYLE $244.52

And you will need new rings to mate with the new cylinder.
3H6000110M PISTON RING TOP $5.15
3H6000120M PISTON RING 2ND $5.15
3H6000130M PISTON RING OIL $5.15

And of course you need a new rod.
3H6000400M CONNECTING ROD ASSY $37.32

But, if the piston is damaged (cracked skirt, etc), you will also need a new piston.
3R4000012M PISTON, STD, 4/5/6A2/B, NEW STYLE (RECESS) $30.77

And that's assuming you don't have any bent valves.
3H6072010M VALVE, INTAKE $14.15
3H6072020M VALVE, EXHAUST $16.72

And you could have damaged valve seats in the head.
3R4B010011 CYLINDER HEAD, MFS/NSF4/5/6A2~B $194.92

And if the crank is bent or damaged, that would also need to be replaced. Only a dial indicator can tell you for sure.
3H6000300M CRANKSHAFT ASSY $154.38

And of course you will need gaskets and stuff, and will need to check/set cam timing.
3H6010051M GASKET, CYLINDER HEAD $7.60
3H6010240M GASKET, HEAD COVER $0.93
3H6023060M GASKET, EXHAUST PORT $1.15
3H6074020M GASKET, OIL PAN $7.33
3H6023050M GASKET, EXHAUST PLATE $2.32
3H6610120M GASKET, DRIVE SHAFT HOUSING $3.48

And that's assuming no fractured bits got into the bearings or the oil pump. You could well exceed the value of the 6-year-old motor in parts alone. So proceed with caution, and check everything over first.

 

[Sea Rider]

Re: Blown cyl on o3' 6hp Tohatsu. Fixable?

If the beast happens to be so damaged, that will need all those quoted parts, better use it as a nice anchor...

Happy Boating

 

[Wee Hooker]

Re: Blown cyl on o3' 6hp Tohatsu. Fixable?

Ok, thanks for teh insight! .All good info. I'm going to pull the crank case off it over teh winter and take a look. If it can be fixed for $300 or so, I may turn it into a project. That said, I can buy one similar for $600 so I'm not going to get to risky with this thing.