Force 150 Rebuild Thread

[ezimmerm]

1989 Force 150 (1508F9A)

Started on the tear down this afternoon.

Carbs/Fuel Pumps off
Throttle Assembly off
Cylinder Head off
Ignition Modules off

Flywheel (Finally F%^&*n off) (make sure you have 2.5lb hammer, puller, heat, crowbar, lots of time, know lots of swear words to get this off)

Run into my first potential part needing replacement. On the stator (see statorbolt picture) one of the nuts has metal raised around it, I would assume this is not normal??? Probably should be replaced?



I'll try and keep taking pictures as I go along for anyone else needing to do a rebuild.

 

[ezimmerm]

Re: Force 150 Rebuild Thread

Alright I've got everything disconnected only the 11 bolts that hold the power head need to be removed.

How heavy is this thing, can 1-2 guys pull it off of there?

If I need a lift where do I hoist it from?

Thanks!

 

[tater76]

Re: Force 150 Rebuild Thread

If the pistons are out I would think one guy could pull the powerhead off the base. However, if it has a, exhaust leg like the three cylinders it may be a pain to lift high enough to clear the base.

 

[jerryjerry05]

Re: Force 150 Rebuild Thread

It has an exhaust housing that extends about a foot into the lower case.#16 is attached to the bottom of the head.Be real CAREFULL when you try to remove this.The bolts wanna break at the first touch.
WD-40 /PB Blaster.Maybe some heat.
It's aluminum and it breaks real easy too.
Gonna need a lift or two real tall basket ball players.
i have a tree with a come along.J

 

[brianvolt7]

Re: Force 150 Rebuild Thread

Did my 120 last year, definitely get a hoist. I took two ladders, 1 10 footer on the ground and 1 6 footer in the boat, and 3 2x6 boards across the rungs. I used a come along, it was a little tricky because the come along wasn?t really designed for up and down movements.

It is difficult to lift because you have to work it around a little bit, so you would be holding the weight while you are maneuvering the unit around.

 

[ezimmerm]

Re: Force 150 Rebuild Thread

Alright I've got everything off, the block is not held down by anything.

I'm going to either buy/rent a lift but where do you lift it from, was I supposed to lift with the flywheel on? Isnt there usually a loop or something to hook on to?

now I'm wishing i had the two cylinder to work on

 

[ezimmerm]

Re: Force 150 Rebuild Thread

double post

 

[ezimmerm]

Re: Force 150 Rebuild Thread

View attachment 110557It has an exhaust housing that extends about a foot into the lower case.#16 is attached to the bottom of the head.Be real CAREFULL when you try to remove this.The bolts wanna break at the first touch.
WD-40 /PB Blaster.Maybe some heat.
It's aluminum and it breaks real easy too.
Gonna need a lift or two real tall basket ball players.
i have a tree with a come along.J

I gave up on WD-40 a long time ago. PB Blaster is the only way I roll when I need to get a frozen bolt off, everyone should have a can of that stuff laying around.

 

[ezimmerm]

Re: Force 150 Rebuild Thread

Finally got the block off the boat and opened up.



Cylinders 2-4 look good with no marks but I did find piston ring material all over the place in there. Pistons 1, 3, 4, 5 all had damaged or broken rings (5 being the worst, 1 was a close second).

Any idea what may have caused this? Interestingly enough on the damaged cylinders/rings all happened at the top of the exhaust ports...is that a known problem area with the 150?

I'll have to wait till tuesday but assuming that I have two cylinders bored .020 over and the other 3 honed, any idea what the cost would be at a machine shop?

 

[tater76]

Re: Force 150 Rebuild Thread

Hey ezimm, so take this as you will, but more than one old timer has told me that 3 to 5 cylinder OB's need to be at least turned over during the winter and in reality started on a monthly basis to keep the rings from sticking. I really had a hard time with this concept, but the more I thought about it, old gas/oil mix turns into gum/varnish over time, you fire the old girl up after a years slumber, your rings are glued in one position. You then try WOT and rings get folded, or so the theory goes. Like I said, this is old timer hearsay, but it is becoming harder to discount as I buy more and more blocks with broken rings. Just a thought.

 

[ezimmerm]

Re: Force 150 Rebuild Thread

Man you would think I have black plague or something. Just called both the marine machine places around here and couldnt even get a price for them to work on the block.

First place I called, I no more then got the word Force out of my mouth and he said just throw it away....needless to say they wont be doing the work.

Is this something one of the automotive machine shops can do, or can anyone recommend a place that I could ship it too seeing as the local shops dont want the work?

Thanks.

 

[coolbikeguy]

Re: Force 150 Rebuild Thread

if you are looking to get the cylinders bored ... any auto machine shop worth its weight should easily be able to take care of it. there is a guy here in lancaster county pa that does auto, boat, motorcycle, lawn mower blocks etc ... and i think frank took some chryslers up to him for work. scott

 

[ezimmerm]

Re: Force 150 Rebuild Thread

The admiral and I decided to repower the old gal instead of fixing the Force (apparently me working on the boat wasn't nearly as much fun for her).

Thanks to everyone for the help over the last couple of years, I learned a tremendous amount about engine operation from working on this one and really appreciate all the help.

 

[jerryjerry05]

Re: Force 150 Rebuild Thread

Any good machine shop can bore the hole.Most marinas weren't trained in Force repairs.Find a Bayliner dealer they might help more.
You really don't need a marine tech anyway.You can do it!!J

 

[venxxxxx]

Re: Force 150 Rebuild Thread

What caused to do a rebuild ? Its alot of work, im about to tackle on a 90hp...but avoiding it as much as possible.

 

[stubtail]

Re: Force 150 Rebuild Thread

Sounds like you've given up on the project, but looking back at the scuffed stator bolt, are there loose magnets or other gremlins floating around on the underside of the flywheel?

 

[ezimmerm]

Re: Force 150 Rebuild Thread

Ven - A piston ring broke and caused some damage to the block, I originally found that after a compression test due to a no start.

Stubtail there might be something else going on but I didnt see any loose magnets. What really prompted all this was while I was looking around I found a hell of a deal on a new non-current etec 130 (the 5 year warranty and free rigging are a bonus too). Should be picking that up next weekend and hopefully have the boat ready to go within 3 weeks.

 

[snowman48047]

Re: Force 150 Rebuild Thread

Force parts can be hard to find, I had a '92 150. Post it on CL and ya might make back some coin.