Newbie Here, Need some engine help... Please... 77' Johnson 35hp

[castires]

I think the cylinder walls will just need honed and that's all. After cleaning the block they don't look that bad. The pistons on the other hand not so much.

I'm going to need a new inner exhaust plate too, it's really distorted. Looks like someone took a hammer to it. I'm sure that wasn't sealing like it was supposed to.

As far as the needle bearings are concerned...they all look really good and were replaced on the original rebuild and are estimated to have less than 40 hours on them. Do you think they're fine to reuse?

 

[castires]

Re: Newbie Here, Need some engine help... Please... 77' Johnson 35hp

Upon review of the rectifier and stator today, I noticed a wire on each where the sleeve has deteriorated and the wire(s) are showing through. I was just going to replace the parts, but at $330.00 for the two, is there anything wrong with just splicing the wires and repairing them? Pics below. The rectifier is the red wire that's exposed.

 

[Rayandrewss]

Re: Newbie Here, Need some engine help... Please... 77' Johnson 35hp

Castires, I just went through a little less than you did on my 79 35 hp Evinrude. Just chaged the statot assembly and will try to run it tomorrow. When you had the overheat problem, was the grommet for the water tube at the powerhead bad ? Just wondering. Great pics......I put some of my own on here at an earlier date. For parts, you might want to look at Amazon.com....they have quite a lot believe it or not. Wish you loads of luck from your neighbor.....Ray

 

[castires]

The grommets look pretty good. I may change them for cheap insurance.

I think what may have done it in was I ran into really shallow water and am wondering if the sand/mud may have kept the water out of the shaft and caused it to tank.

It wasn't immediately after that, but I think it may have been the trigger.

Good luck on your build as well. It's been really fun and educating thus far. Can't wait to begin the assembly. But I'm heading out of town for the holidays, so it may not be until I get back.

 

[jasper60103]

Re: Newbie Here, Need some engine help... Please... 77' Johnson 35hp

Upon review of the rectifier and stator today, I noticed a wire on each where the sleeve has deteriorated and the wire(s) are showing through. I was just going to replace the parts, but at $330.00 for the two, is there anything wrong with just splicing the wires and repairing them? Pics below. The rectifier is the red wire that's exposed...

Yea, pretty spendy. I would repair it, and use some heat shrink tubing or liquid electrical tape.

 

[castires]

Sounds like a plan then. I'll fix those up while waiting on my parts.

 

[jasper60103]

Re: Newbie Here, Need some engine help... Please... 77' Johnson 35hp

Hey, Chris.
I see you're very organized, looking at your display of parts.
Forgot to say, good catch on finding the worn stator wiring.
That would have definitely caused you some problems eventually.

Also, I wanted to ask a favor.
As long as you have everything torn down.
Would you mind taking a picture of the sensor (#11)
and coil (#21)? I don't think I ever seen those parts before.
If they're attached to the plate (#8), a pic of the
assembly would be fine too. Thanks, Jasper.

http://www.marineengine.com/parts/j...l=35E77C&manufacturer=Johnson&section=Magneto

 

[castires]

No problem. I'll take a few pics of those tonight when I get home.

 

[castires]

Jasper...

I don't have those parts, is it possible since mine is an electric start that's why?

I just have the stator.

 

[Home Cookin']

Re: Newbie Here, Need some engine help... Please... 77' Johnson 35hp

Re: "I think what may have done it in was I ran into really shallow water and am wondering if the sand/mud may have kept the water out of the shaft and caused it to tank."

probably not; the reason the OMC's are so popular and long-lasting is they are not temperamental about that sort of thing. One thing to remember is that when you are moving forward, all that stirred up mud is behind you. But many's the day the pisser was shootnig out black water, no problem. Not that you shouldn't avoid it, but you sometimes have to.

On the wire repairs: I'd try the repairs, but keep an eye on them; they can corrode from the inside so easily. One of those life-long problems in salt water. Your parts would be about the value of the motor. But I'd get it running first, then keep an eye out for cheaper parts down the line

 

[Rayandrewss]

Re: Newbie Here, Need some engine help... Please... 77' Johnson 35hp

Jasper.....see my thread " wrong stator ". I put a pic of both stators there.....ray

 

[jasper60103]

Re: Newbie Here, Need some engine help... Please... 77' Johnson 35hp

Jasper...

I don't have those parts, is it possible since mine is an electric start that's why?

I just have the stator.

Chris, you're correct. I didn't realize that. Thanks.

Ray, thanks for the pic.

 

[castires]

Re: Newbie Here, Need some engine help... Please... 77' Johnson 35hp

Can someone please verify that the original owner/previous rebuilder installed the pistons in the correct direction? The pic below is how I found it when disassembling:

The motor ran fine before, so I'm assuming he did, but when I look at it, it seems that you'd want the piston with the high side away from the spark plug, to alleviate any chance of contact...

Just wanted to verify prior to assembling it.

Thanks!

 

[castires]

Re: Newbie Here, Need some engine help... Please... 77' Johnson 35hp

In the picture above, the exhaust is on the left side, intake the right.

 

[jasper60103]

Re: Newbie Here, Need some engine help... Please... 77' Johnson 35hp

Can someone please verify that the original owner/previous rebuilder installed the pistons in the correct direction? The pic below is how I found it when disassembling:

...
The motor ran fine before, so I'm assuming he did, but when I look at it, it seems that you'd want the piston with the high side away from the spark plug, to alleviate any chance of contact...

Just wanted to verify prior to assembling it.

Thanks!

I say you're good to go. I have the gash mark to prove it, LOL.
Actually, the gash is from the compression tester, my bad.
Still runs like a champ though.

edit: Did you decide to replace the head or have it flattened?

 

[castires]

I'm taking the block, head, and head cover to the machine shop tomorrow. I guess depending on what they say will determine if I replace the head or not. I'm hoping not though.

 

[castires]

Are the 25hp and 35hp heads identical?

If I can't get mine decked, the only heads I can find new are for the 25hp, but they appear to be identical.

 

[jasper60103]

Re: Newbie Here, Need some engine help... Please... 77' Johnson 35hp

Are the 25hp and 35hp heads identical?

If I can't get mine decked, the only heads I can find new are for the 25hp, but they appear to be identical.

For 1977, the 25 and 35 cylinder heads have different part numbers. I would look-up the model year and make sure the part numbers match before buying.
Here's the one on ebay I posted earlier.
http://www.ebay.com/itm/Johnson-Evi...945636&pt=Boat_Parts_Accessories_Gear&vxp=mtr

 

[castires]

Good evening all!

I'm back from vacation, so the build has resumed.

I took the block to the machine shop today. It's getting bored .040 and will receive wiseco pistons.

I've got the powerhead gasket set, and seals on order.

Where can I find the OMC gasket sealer or an equivalent?

What is a good degreasing bath for all the parts prior to reassembly?

 

[castires]

While I'm at this, I thought I'd take a look at the carb as well. It was rebuilt the last time (by my friend), but I want to make sure it's setup correctly after all this work.

Is there a setup guide? Or can someone help me with this?

I wasn't worried about it considering it was recently rebuilt, but I read a post on here about someone running their boat and feeling like they hit a log or something. It was something to do with the carb as they never hit anything.

The day my motor went, this exact same thing happened to me earlier in the day. But I didn't know what it was as everything appeared normal and ran fine afterwards until it burnt up.

I just assumed I hit something or whatever.