Johnson 55el77d rebuild

[CobisCaller]

I decided to start another thread for this motor I had asked about earlier.

I stripped the motor down and found the lower piston ring had stuck and scored the cylinder wall. I was told the motor had been rebuilt in the past, and that was verified with it currently having .020 pistons now.
My machinist said he thought a .030 boring would remove the scoring but he may have to bore to .040. Wiseco makes pistons for both sizes.
My question is will I need to change anything else with the motor or carb jets with a .040 overboring?
Just wondering as that factory parts only go to .030.
Thanks for the help

 

[ronward]

Not sure about outboards, but my experience with other engines is .040 is pushing it. Maybe consider a different motor with a lot less wear, probably cheaper???

 

[CobisCaller]

Hey thanks for the response.

I have already weighed the costs of repair versus replacment and would like to overhaul this one if possible.

I was wondering if anyone had experience with any issues with boring to .040 over specifically. If it won't work without a bunch of other changes or not?

Thanks again

 

[racerone]

Find another block or bore to 0.040 O/S and open high speed jet by 0.002"

 

[CobisCaller]

Okay thanks for the info!
I am waiting to hear from the machine shop on how far it needs bored to remove the scoring. I'll reply back.

 

[CobisCaller]

Okay the machinist said .030 over will do. He also thought the crankshaft and bearings looked good.
I ordered 2 Wiseco pistons and they are on the way.
As for the rest of a parts list I have
1. Complete seal kit
2. Stator coil assembly(found sticky goo leaking from coil upon teardown)
3. Carb rebuild kits

Any other suggestions of "while you're in there, change this" kinda things?

Thanks again