Evinrude 150 rebuild project

[etd66ss]

I disassembled my 1978 150849S 150 HP which has a 1984 powerhead on it.

I cleaned and inspected all the parts, the link to the .pdf shows my findings.

http://www.infinity-universe.com/~dev/WhiteDwarf/Evinrude/Specifications.pdf

I'd like a mechanic's opinion on the cylinder bores, on whether or not the gouges can be cleaned up, knowing the measured sizes of the #1 & #4 bores. I am guessing at the depth of the gouges, as I have no way to measure them accurately.

I figure I can try honing with a precision hone similar to this one: http://www.amazon.com/Lisle-16000-Small-Cylinder-Hone/dp/B000P1802O But for 3.5 in bore of course.

I figure I can try to hone, if the gouge is not removed by the time I get to 3.5030 on the bores, I'll just have the block bored .030 over. That would be a shame, as 4 of the 6 cylinders are good, and 5 of the 6 pistons are good.

As far as the crankshaft, I guess it's either find a good used one on eBay, or send mine out for spray welding & grinding.

 

[emdsapmgr]

Re: Evinrude 150 rebuild project

It is perfectly acceptable to overbore one or more cylinders, leaving the others at standard bore. An overhauled engine will run with vertical light scratches in the bore, if honed and new rings. The long term durablility will be less on that cyl, as exhaust gases (and heat) will pass down that scratch and will affect (carbon up) the ringsets over time. That's not a recommended option. It's your call on how you want to handle it, perhaps based on how long you plan to keep the engine.