Power head catches on fire, dumps some beer, keeps burning, shrugs, keeps going at it! Great video, used as reference for my tear down and rebuild project.
Just wanted to say great videos stu been watching for couple of years, given me the confidence to do basic jobs, hubs and bearings, stirring jam, water and fuel pump change and loads of others now thinking about it. Saved me loads of money and given me confidence while using the boat. Nice one thanks Ste
I absolutely love that you present your videos 100% accurate. Its good that you show the ups and downs that us mechanics go through day in and day out. I have worked on everything imaginable with the exception of out board motors. I love your channel, keep up the great work!
Interesting dissection. Thanks for going through the complete process even after you basically knew it was toast. FWIW, I was taught to look in the spark plug holes, and take the head off if necessary, when the engine was seized, so you could specifically look for chewed up piston heads.
DANGAR, Love those wiggle head extensions! I was working a job with a 2nd man & he pulled out a wiggle head extension for the work. I had never seen one before. He let me examine it & use it & I was sold! Next day at work, he walked up & handed me a package of 3 wiggle headed extensions : a 12" a 6" & a 3". It was such a nice gesture I bought us lunch. I use them regularly in my home shop now I am retired. Dig you videos. Metrics always confuse me. When you say your pulling a 10 mil bolt I dunno if you mean a bolt with a 10 mil head OR a bolt with a 10 mil shank. I'm learning. It's a joy to watch a man do good work. Keep it up. viewing your videos from California, USA.
Community Service Announcement Please turn away at 16:55 for approx 5 seconds Stu was frustrated and wasn't thinking straight... Never, EVER use your beer to put out a fire... NEVER !!!! Even if it does put out the fire... You have no beer... ha ha ha ha Great video as always - I really felt for you and could see your frustrations...
Excellent video bro. I enjoy them all because even though you are not fixing that 40 I get to see over and over what these outboards look like from the in out in detail
By the way great tear down video showing what can happen to the inside of a outboard engine. Even though not cost effective to rebuild it at least shows folks good care with maintenance is a must with these motors. Anti-seeze is a good friend.
Really enjoyed that engine breakdown and covered a lot of the common problems. It was a shame to scrap the motor but the only option viable. I got to think OMG how will you remember where all those parts go back together. Great
On one hand, I'm elated that you did a full tear-down of this motor, because it happens to be the same model (and year) of mine! On the other hand, I'm super sad to see that you are calling it a lost cause, because I won't get to see you do any more repairs on a 40 HP Johnson from 1999. Either way, great video Stu!
I just rolled with laughter when you went for a beer then used it as a fire extinguisher!!! this was a great video because it showed how miserable a corroded motor is to take apart and how un-handy some of the bolt locations can be. But to be frank here, I have never seen that kind of damage before. WOW. I personally would not attempt a rebuild on this one even if it were fairly new. I love watching your videos because they are so educational, and yes wear you safety equipment.
I love your videos. I like your realistic portrayal of the difficulties of simple tasks that can really take the wind out of your sails. I've made a few videos outboards and mechanical things, and in one of them I had a very similar problem with a stuck flywheel. Needless to say, your solutions are almost always more elegant than mine ;)
Another great vid Stu, really like how you show the reality and frustrations pulling things down. So many other videos have all the drama's edited out.
The happiest day of my life was when we traded our old Johnson for a set of self-tailing winches. But I still feel like I could have fixed it. Thanks for the great video DangarStu.
Lots of work to tear this one down Stu. When you have a bunch of bolts on an assembly the LAST ONE will always seem to give you issues to remove! I thought it was just my luck! I have all the same tricks. Heat, Plasma cutter and air chisel...and when all else fails...anger and brute force! 😊
Hey Jack, yes, why is it always the last one??? I must say though, when it takes me ages to find something I always keep looking for a bit after I have located it so it isn't always in the last place I looked. ;)
Love the video old mate! i understand most would just simply swap over to another newer outboard due to (older motors) exceeding the value on what they are worth to rebuild but some of us diehards still prefer the older outboards and sometimes they have a sentimental value and we simply just can't let go of them! today's day and age, most things are simply disposable and throw away, good to see your having a go :)
I too like the idea of repairing old things rather than just throwing them away. This is one of the benefits of DIY is that often it becomes financially viable if you are doing all the labour yourself, including hunting around for some second hand parts etc.
What a great video, one of the best you have done! For me, it gets across the point really well that outboards operate in a really harsh environment, and when the years accumulate and something goes bad (e.g. bearing failure), then you find parts are going to seize and / or break, and very likely the motor is beyond economic repair. Many thanks.
Looks like you had a tough day. Sorry, that some days are just like that! I just had a Johnson 40 HP that had perfect cylinders, but would not rotate completely. I figured it was a ring stuck or a bad bearing. Was going to take one with a scored cylinder, combine the two and get a good engine out of all the parts. A car mechanic friend was over, and decided he could get it free. He did, but scored a perfect cylinder while doing it. Lesson learned - keep car friends away from boat motors after they have had a few! This week, I had a 115 with perfect compression, hot spark, good timing, etc, etc. It runs great at speed, but it simply would not idle. Once above 1500 rpm, it runs like a champ. I did many, many things, but nothing helped. Finally, after having two other mechanics over to brainstorm with me, and getting nowhere, one asked if I would sell it to him as a test monkey. I did, and now he has it. Only the second motor in memory that I simply couldn't figure out. Does not feel good! My theory is that is has a vacuum leak on the bottom of the motor, probably the bottom seal. Somewhere the spray can't reach. At higher RPM, the engine produces enough vacuum to run properly, but at idle, the leak is too much, and it just dies out. No sneezing, coughing or popping, it just slowly dies. That's my theory, at least. It will be curious if Josh can figure it out. I hope he can. Thanks for the video, as usual!
Bummer about the Johnson, don't you just love it when you mates help! Sounds like a good theory with regards to the 115. Vacuum leaks do tend to have much greater effect at idle. Some outboard really are baffling some times.
Good video, I rebuilt a 2002 50hp Johnson about 5 years ago. I also had the 2 bolts that would not break loose. I had to drill them out to get the engine off. After paying for the machine work, parts and gasket, for another 3 grand I could have bought a new outboard.
Bloody good vid...dead right re the cost. And its nice to know everyone gets impossible busted/sheared/seized solid bolts and systems , that defeat us all at times.
Got one coming up possibly. A neighbor that lives nearby has a 83 8hp Suzuki that is seized. I told him I would help him try to get freed up but if not will take it if he plans on dumping it. I would take it apart and use a press to push it piston back and forth with lots of lube and heat if needed. If I'm lucky with cylinder cleaning and the piston just needs new rings with replace the main crank bearing and put it back together? Maybe? It would make a good video either way😁👍
Hi, I had that exact problem with the fly wheel turning a bit then catching. Was unable to do a complete rotation of the engine. And had the same problem with the power head bolts rusted and rounded off. Cut my bolts off with a dremmel tool and cut off wheel and little mini grinder. What a job. I am pleased to say that my problem was a rusted ring on the lower piston that was catching a port. I got lucky. Already bought the power head gasket kit and Johnson manual and rings from your sponsor marineengine.com . Thanks for the video.
My wish is that you use safety goggles / glasses when using power tools. That was close 1:39. Our eyes are delicate. A work associate long ago was using a air chisel and a sliver of metal shot into his eye and blinded him in that eye for life. I'll never forget that story he told me about that. Great video Mate.
I'm a bit slack with safety glasses and had some close calls, but it's funny how the eye seems to blink just in the nick of time... Almost like it's got super speed or something.
I feel your frustration mate. Glad it was you and not me, even though I enjoy a challenge. Cheers mate, good work. I would suggest that beer only works as a firefighting aid if it is inside the operator. Hahahaha Looks like I will be down your way round the end of Audust to mid Sept. I'll keep you posted.
I realize you work on several outboard brands, but the OMC universal flywheel puller is a must for getting these flywheels off. 99% of these removal headaches will be avoided for sure. That was a very creative method for splitting the crankcase with the stuck powerhead bolts! Please be sure to remove the crankcase alignment taper pin first though, before the crankcase bolts, the case halves will then split easily with just a few raps on the crank with a heavy plastic mallet. Too bad this engine is a finished for sure, unless you can find a decent used powerhead...
Yes, having the exact right OEM tool definitely makes a lot of jobs easier, that's for sure. Unfortunately we are primarily an automotive shop so all the money goes into tools like spring compressors and radiator pressure testers that are no use at all on these outboards! As you say, second hand powerhead from a wrecker is probably the best way to get this motor up and running again.
I always treated the flywheel "puller" more like a tool to put tension on the flywheel. Put the tension on by hand so it's fairly snug then tap (pound?) on the flywheel. Little more tension and some oil-like spray and maybe a little heat and more tapping. Keep doing this a bit at a time rather than doing it all at once. Less chance of breaking a bolt and/or splaying out the center bold.
just as an aside kiekaffer made very powerful outboards. i had 2 28horse engines. they had a spring relief deal instead of shear pins. the design flaw was the spring steel would chew up the aluminum housing and get sloppy. unrestricted the springs would slop and break. the fix was to machine the lower unit and sleeve it. pretty simple but never done . those 2 bladed buggers would go like hell. lots of good power heads. no lower units. oh well!
The top of that piston was Joe Mangled it even had some rollers embedded in the piston.It reminds me of the USS Eldridge which had sailors embedded in the metal after the ship reappeared after having disappeared during the US Navy experiment on attempting to make a ship invisible.
Hahaha Best one yet Stu.. Loving the flare-up Not my words , but great man said today " that beer is known for its fire retardant qualities (being a mid strength) That Johnno is rooted for sure. Looking forward to the seized bolts episode
Had an old duffer explain to me years ago to not use the puller to actually pull of the flywheel but to use it to put a strain on it and tap the flywheel with a non-metal hammer. Keep adding a little more strain (half a turn) and keep tapping on the wheel. A little lube and a little heat maybe but go slow with the puller.
That certainly is a good technique. Need to be careful with heat due to the wiring beneath the flywheel but it is amazing how often a relatively light tap will release something once it is under load.
I rebuilt a Johnson "Big Twin" 40hp (vintage, from the 1960s) and my first clue something was wrong was finding needle bearings lodged in the sparkplug, between the threaded housing and the ceramic insert containing the electrode. Was a real "holy sh!t" moment, considering I was riding in the boat not 5 minutes before finding the bearings lol
@@DangarMarine No, but it was rather funny, looking back on it. Ended up getting it re-sleeved, replaced pistons, rods, everything. Used that engine for another couple years and sold it for a fair bit more than I paid for it. ;) Edit: Sorry to hear about the hardstand issues, hoping to see more on the steel tub once it's up and dry, was what drew me to your channel. Best of luck Stu
my 2013 150 opti dropped a piston and the powerheads bolts were just as stubborn Stu..i gave them a good working over laterally with the air hammer and penetrol and managed to shake the corrosion loose..so much for factory corrosion control hey..Nice work anyway mate
Thanks Stu, I'm having the same issues with a 1996 Evinrude 60hp. Think I will try take it apart , but not going to spend lots of money on parts . Will give it a crack!
I had the same problem with my Johnson 25hp. I had two bolts stuck. I cut them the same way. The drive shaft was stuck also. I tied the power head to the back of my truck and tied the lower end to my house. I drove off and still had to beat it with a sledge. What a nightmare. This is usually all caused by poor maintenance. No water to the jacket. Change your water pump every season folks. In your case a bearing.
Enjoy your videos and you are obviously a master mechanic. It was great seeing you do the "autopsy" on that engine and your technique and work for getting around the stuck bolts etc. But wouldn't it have been easier to put a fiber optic scope into cylinder and see the damage to the piston from the crankshaft bearings ?
Wore some over my street glasses yesterday drilling a dowel pin hole in a steel pin. drill bits can break and sometimes shatter. had a spring hit me in the face not long ago. didn't hurt but example stuff can fly so better safe than sorry.
Can be a variety of things, but this outboard had sunk in very muddy salt water about six months ago. Combine that with being almost 20 years old and used every day...
Can be a variety of things, but this outboard had sunk in very muddy salt water about six months ago. Combine that with being almost 20 years old and used every day...
Stu, did you see how close that bolt or ? came to hitting your eye? You might want to think about safety glasses mate. Great video! One thing is for sure whether down under or in the States tough jobs require a beer in your tool box.
Dangar Marine Haha, well at least you were wearing your safety condom on the one hand, I mean you could easily do with one eye but how you going to work if you can't hold a beer and a screwdriver at the same time?
Oh man. I thought you were going to throw a couple of snags on the oxy baryby for a moment their... I know the feeling... I worked with and on motors and adjoining bits for twenty years in my own business and this reminds of why I never want to go back. Wouldn't be so bad if there weren't bills to pay. And don't worry bout cross faces. I had them, plus cross words plus cross flying things from tools to well anything ... it's a tough gig. But nothing a day on the water with a few coldies won't fix. You did well! coltrump🇳🇿👍🏻👍🏻👍🏻
Another effective method for freeing stuck driveshafts on the 2/3cylinder OMCs with exposed upper driveshafts is to attack the upper driveshaft under the powerhead with an air hammer while an assistant gently pries down on the gearcase. The best way to avoid this situation is proper maintenance to begin with. Salt water engines should have the gearcase removed every couple of years so the splines can be cleaned and relubed with OMC moly lube. Needless to say, the impeller should be changed while the gearcase is off as well. As a OMC rep, I was continually frustrated by techs who skipped over this important step when doing water pump jobs, especially on salt water engines...
For sure. The gearboxes come off all the outboards we service at least once a year for an impeller inspection / replacement and cleaning the old grease out from the splines then adding new is definitely something we do as we know we are likely to be the next people who have to take it off!
hi Stu this video is very informative even more so because I have a 50hp Johnson but mine seems to be fine so far no problems with it at all what I'm wondering is if any of the parts off this motor would still be useable & would you part it out in particular starter motor set up & Power trim / Tilt set up as my outboard is Manual start & manual tilt would hate to think they were just thrown out not that I think you would if they were of any use thanks for the work you put into the videos for our entertainment
Hi Stu, excellent video. I have a Yamaha 15 2 stroke where the main bearing failed. Is there a way to remove the centre bearing? How do you split the crank. Not sure if it’s worth repairing but I like to have a go just for the craic. Any help would be greatly appreciated. Thanks
Thanks Lorcan. Unfortunately I don't think you can replace that centre bearing. I spent ages trying to find an angle I got get a shot at pressing the crank apart but no luck. Next time I was at Yamaha I asked about it because I thought it was odd and they said no go, whole thing needs to be replaced.
Learned a lot about perseverance. What good parts will you save? Do the bolts and screws go in a coffee can, or are you super organized with lots of little bins and drawers? There is a mechanic in my town with a collection of a 100+ complete engines, some running... for parts.
Quite a lot got saved off this outboard. I don't keep the midsection due to lack of room, but the gearbox and all the smaller parts that got taken off the powerhead get stored. My bolt box is just a jumble though. The only way I divide them up is metric and non metric.
Hello I am looking for a tear down and rebuild of a 1996 Johnson 200 HP Ocean Runner video or book. I would like to rebuild my Johnson outboard. Any information would be great! Love your videos! Thanks
thank you for the vid. I have a 96 evinrude 40. Can you put one of those onboard battery chargers you installed a little while ago on this type of motor?
Yep, sure can. If you take a look on MarineEngine.com you will be able to find the regulator rectifier that goes with your motor and order is separately.
Hi. I wonder if you could please make a video. Of how to start a outboard motor on a stand ? I recently bought a 1998 ish mercury black max 150 hp. I have it on a stand but not sure how to start it . It's the electrical i'm not sure of. Or maybe you could explain it to me on this post . Either way it would be greatly appreciated
Hi Tom, that would be a good video. I normally just connect the forward controls to the outboard and turn the key as normal, but if you don't have that you can make a remote starter like this ruclips.net/video/LZGnKldqDsA/видео.html
Pouring a kettle of hot water can work really well instead of using a flame. Lots of energy in a few litres of boiling water its surprising what it can do.
Hi Stu, longtime watcher. I have a mercury seapro 25 that runs for a minute and locks up, can be restarted but repeats. Appearently they dont like running on the throttle stop for 30 mins constant. The motor cost me chips, is running a richer mix and a hotter plug a viable option? Do you have any suggestions. Cheers mate! Matt, Newcastle. NSW
Dangar Marine . Hi again Stu thanks for the reply, when it stalls the flywheel does still turn freely as could be re started. A water pump sounds like a good place to start as im unsure of its history and i know she had been out of the water for a few years. Kind regards . Matt
Love the channel, I know how long that editing can take. Next time put a borescope in through spark plugs and have a look at the top of the Piston, might save yourself a teardown. I got a cheap $20 that hooks up to your smartphone, 7mm tip with LEDs in it. They have them in whatever length you need
This story is sort of proof that despite the skill of the surgeon, not every patient can be saved. It's unfortunate, but I do concur with your assessment that it would be more money than it's worth. How long would you guess this motor had run (pounding pieces between piston and head) before quitting?
The owner reported that it had been running rough the day before and then seized. The average trip to the mainland is only 10-15 minutes so I would say 30 minutes at most.
Stan, I agree. And there are some people that I am sure surgeons would cut their monetary losses on if the person was on the table as well. I know have their oath , but it really should be called the Stop correcting "hypocrite" oath for a lot of them!
i have got a recondition 350 chev i am putting back in my boat but am looking at putting a outboard on instead .It may be more economical but the thought of seized bolt puts me off somewhat
I really enjoyed this video Stu! Thanks for the content. Rumor has it these old Johnrudes are known for bearing failures. If the bolts wouldn't have given you any trouble, how many hours do you think it takes to strip, rebuild, and reassemble a 6cyl Johnson like the one you have here?
Great video here, this helps me understand these motors better. I have an '80-something 60HP Johnson 2 stroke that died yesterday. Running nice and smooth around 2k rpm then it stopped quickly. It had run nicely last year, but this was the 2nd outing this year. Upon manually turning the flywheel I discover quite a bit of grinding when turning in the running direction, but no grinding in the other direction. Of course it is in neutral. I can turn it 360 degrees, and like I say it turns freely in the reverse direction. Nothing getting jammed under the flywheel, which is off now. Because it turns without grinding in the reverse direction, I'm thinking it's not bearings. Am I crazy for thinking this is worth taking the lower off, then the power head to see if it then spins freely in the other direction? Maybe peek in through the reed valves with a scope. I think the motor has just been in freshwater, so bolts haven't given me too much grief...jinx. It also will idle intermittently until it abruptly stops. Tried that 3 times now before discovering my grinding. I'm thinking, hoping something might be just binding the driveshaft???? IMO if it's bearings I will feel grinding in both directions.
Power head catches on fire, dumps some beer, keeps burning, shrugs, keeps going at it! Great video, used as reference for my tear down and rebuild project.
Just wanted to say great videos stu been watching for couple of years, given me the confidence to do basic jobs, hubs and bearings, stirring jam, water and fuel pump change and loads of others now thinking about it. Saved me loads of money and given me confidence while using the boat. Nice one thanks Ste
Thanks for watching Steve, glad to hear the videos have been helping you with your boat. :)
I absolutely love that you present your videos 100% accurate. Its good that you show the ups and downs that us mechanics go through day in and day out. I have worked on everything imaginable with the exception of out board motors. I love your channel, keep up the great work!
Thanks Tim, glad you like the channel. :)
Interesting dissection. Thanks for going through the complete process even after you basically knew it was toast. FWIW, I was taught to look in the spark plug holes, and take the head off if necessary, when the engine was seized, so you could specifically look for chewed up piston heads.
For sure, if it was a job for a customer you would put the bore scope in a plug hole and pull the pin before spending any time or money.
I don't even like working on Marine engines, but this guy is very good at teaching...
Thank you, now I'm randomly watching videos
Thanks mate, glad you are enjoying the vids. :)
DANGAR,
Love those wiggle head extensions!
I was working a job with a 2nd man & he pulled out a wiggle head extension for the work. I had never seen
one before. He let me examine it & use it & I was sold! Next day at work, he walked up & handed me a package
of 3 wiggle headed extensions : a 12" a 6" & a 3". It was such a nice gesture I bought us lunch. I use them
regularly in my home shop now I am retired.
Dig you videos. Metrics always confuse me. When you say your pulling a 10 mil bolt I dunno if you mean a bolt with a 10 mil head OR a bolt with a 10 mil shank. I'm learning.
It's a joy to watch a man do good work. Keep it up.
viewing your videos from California, USA.
Can't believe the bearing rollers found their way to the top of the piston!!!! Very interesting video. Thanks.
Hey Keon, yeah, they come up through the transfer port the same way the fuel and air gets up there and then all hell breaks loose!
Thanks for the reply. Haven't seen the GreenMachine in a while. Hope all is good there..:)
Community Service Announcement
Please turn away at 16:55 for approx 5 seconds
Stu was frustrated and wasn't thinking straight...
Never, EVER use your beer to put out a fire... NEVER !!!!
Even if it does put out the fire... You have no beer... ha ha ha ha
Great video as always - I really felt for you and could see your frustrations...
I just lost my mind for a moment, I don't know what I was thinking. ;)
OK, Forgiven this time... :P
Excellent video bro. I enjoy them all because even though you are not fixing that 40 I get to see over and over what these outboards look like from the in out in detail
Thanks Trevor!
By the way great tear down video showing what can happen to the inside of a outboard engine. Even though not cost effective to rebuild it at least shows folks good care with maintenance is a must with these motors. Anti-seeze is a good friend.
For sure. Taking bolts out and adding a bit of antiseize is something I've seen people do the day they buy a new outboard.
Man what a hassle !! You really went in like a surgeon .. you do amazing work sir..
Really enjoyed that engine breakdown and covered a lot of the common problems. It was a shame to scrap the motor but the only option viable. I got to think OMG how will you remember where all those parts go back together. Great
I bet people that work around you have found your knowledge very useful.
And they certainly teach me many things I don't know. It's always great to share knowledge. :)
On one hand, I'm elated that you did a full tear-down of this motor, because it happens to be the same model (and year) of mine! On the other hand, I'm super sad to see that you are calling it a lost cause, because I won't get to see you do any more repairs on a 40 HP Johnson from 1999. Either way, great video Stu!
Thanks Corey, don't worry, I'm sure there will be others.
I just rolled with laughter when you went for a beer then used it as a fire extinguisher!!! this was a great video because it showed how miserable a corroded motor is to take apart and how un-handy some of the bolt locations can be. But to be frank here, I have never seen that kind of damage before. WOW. I personally would not attempt a rebuild on this one even if it were fairly new. I love watching your videos because they are so educational, and yes wear you safety equipment.
Yes, failed bearings do do more damage than just the bearing itself unfortunately.
we have all been there!
I love your videos. I like your realistic portrayal of the difficulties of simple tasks that can really take the wind out of your sails. I've made a few videos outboards and mechanical things, and in one of them I had a very similar problem with a stuck flywheel. Needless to say, your solutions are almost always more elegant than mine ;)
Another great vid Stu, really like how you show the reality and frustrations pulling things down. So many other videos have all the drama's edited out.
If I edited all the things that went wrong out of this video it would just be an intro and an outro. ;)
The happiest day of my life was when we traded our old Johnson for a set of self-tailing winches. But I still feel like I could have fixed it. Thanks for the great video DangarStu.
That's the thing, everything IS fixable, it's just a matter of how much you want to put into it. Enjoy the winches! ;)
Lots of work to tear this one down Stu. When you have a bunch of bolts on an assembly the LAST ONE will always seem to give you issues to remove! I thought it was just my luck! I have all the same tricks. Heat, Plasma cutter and air chisel...and when all else fails...anger and brute force! 😊
Hey Jack, yes, why is it always the last one??? I must say though, when it takes me ages to find something I always keep looking for a bit after I have located it so it isn't always in the last place I looked. ;)
Love the video old mate! i understand most would just simply swap over to another newer outboard due to (older motors) exceeding the value on what they are worth to rebuild but some of us diehards still prefer the older outboards and sometimes they have a sentimental value and we simply just can't let go of them! today's day and age, most things are simply disposable and throw away, good to see your having a go :)
I too like the idea of repairing old things rather than just throwing them away. This is one of the benefits of DIY is that often it becomes financially viable if you are doing all the labour yourself, including hunting around for some second hand parts etc.
What a great video, one of the best you have done! For me, it gets across the point really well that outboards operate in a really harsh environment, and when the years accumulate and something goes bad (e.g. bearing failure), then you find parts are going to seize and / or break, and very likely the motor is beyond economic repair. Many thanks.
Thanke mate, the years in salt water certainly don't do an outboard any favours.
Best video yet ! Beer +fire and not a barbie to be seen.
Thanks Matt!
Looks like you had a tough day. Sorry, that some days are just like that!
I just had a Johnson 40 HP that had perfect cylinders, but would not rotate completely. I figured it was a ring stuck or a bad bearing. Was going to take one with a scored cylinder, combine the two and get a good engine out of all the parts. A car mechanic friend was over, and decided he could get it free. He did, but scored a perfect cylinder while doing it. Lesson learned - keep car friends away from boat motors after they have had a few!
This week, I had a 115 with perfect compression, hot spark, good timing, etc, etc. It runs great at speed, but it simply would not idle. Once above 1500 rpm, it runs like a champ. I did many, many things, but nothing helped. Finally, after having two other mechanics over to brainstorm with me, and getting nowhere, one asked if I would sell it to him as a test monkey. I did, and now he has it. Only the second motor in memory that I simply couldn't figure out. Does not feel good!
My theory is that is has a vacuum leak on the bottom of the motor, probably the bottom seal. Somewhere the spray can't reach. At higher RPM, the engine produces enough vacuum to run properly, but at idle, the leak is too much, and it just dies out. No sneezing, coughing or popping, it just slowly dies. That's my theory, at least. It will be curious if Josh can figure it out. I hope he can.
Thanks for the video, as usual!
Bummer about the Johnson, don't you just love it when you mates help! Sounds like a good theory with regards to the 115. Vacuum leaks do tend to have much greater effect at idle. Some outboard really are baffling some times.
Good video, I rebuilt a 2002 50hp Johnson about 5 years ago. I also had the 2 bolts that would not break loose. I had to drill them out to get the engine off. After paying for the machine work, parts and gasket, for another 3 grand I could have bought a new outboard.
Yep, fixing an outboard can get very expensive very fast unfortunately.
Bloody good vid...dead right re the cost. And its nice to know everyone gets impossible busted/sheared/seized solid bolts and systems , that defeat us all at times.
Thanks mate, plenty of corrosion on these saltwater outboards!
On the bright side, the clock repair is great; still going strong.
I like someone who always looks on the bright side. :)
Got one coming up possibly. A neighbor that lives nearby has a 83 8hp Suzuki that is seized. I told him I would help him try to get freed up but if not will take it if he plans on dumping it. I would take it apart and use a press to push it piston back and forth with lots of lube and heat if needed. If I'm lucky with cylinder cleaning and the piston just needs new rings with replace the main crank bearing and put it back together? Maybe? It would make a good video either way😁👍
Great Video! I like your idea about doing a stuck bolt/stripped threads video too.
Thanks Sean, yep, looking forward to filming that one.
Hi, I had that exact problem with the fly wheel turning a bit then catching. Was unable to do a complete rotation of the engine. And had the same problem with the power head bolts rusted and rounded off. Cut my bolts off with a dremmel tool and cut off wheel and little mini grinder. What a job. I am pleased to say that my problem was a rusted ring on the lower piston that was catching a port. I got lucky. Already bought the power head gasket kit and Johnson manual and rings from your sponsor marineengine.com . Thanks for the video.
HI mate, glad it was only the ring but I feel your pain when it comes to rusted and rounded off bolts. Thanks for using marinengine.com! :)
I just recently rebuilt my evinrude 110 your videos were very helpful in the process keep up the good work and thanks for the info videos
I'm really learning a lot from your concise explanations. Great videos Stu.
You had em rolling on the deck up here in New Hampshire with your Matrix come back Stu....keep up the good work.
Oh good, I wasn't sure whether to use the safety contact lens line instead. ;)
My wish is that you use safety goggles / glasses when using power tools. That was close 1:39. Our eyes are delicate. A work associate long ago was using a air chisel and a sliver of metal shot into his eye and blinded him in that eye for life. I'll never forget that story he told me about that. Great video Mate.
correction: 4:39. not 139
I'm a bit slack with safety glasses and had some close calls, but it's funny how the eye seems to blink just in the nick of time... Almost like it's got super speed or something.
Fortunately my eyes are getting worse each year so I'll be wearing glasses full time soon anyway. ;)
I didn't see any problem u were wearing ur Australian Safety glasses LOL
You only have to use safty equipment the weak before you retire . Do you know anyting about murphey's law.
Love you work with beer and slug! Beautiful piston head!
I figured after I saw the big gash you were going to junk that one.you still have some nice parts
I feel your frustration mate. Glad it was you and not me, even though I enjoy a challenge.
Cheers mate, good work. I would suggest that beer only works as a firefighting aid if it is inside the operator. Hahahaha
Looks like I will be down your way round the end of Audust to mid Sept. I'll keep you posted.
Good point Bruce, my main concern should have been making sure the fire didn't spread to my stomach! Sounds good re trip.
Keep up the vids! Your videos have made me an expert on outboards! Haven't missed a video
Thanks mate, glad they've been helping you. :)
I realize you work on several outboard brands, but the OMC universal flywheel puller is a must for getting these flywheels off. 99% of these removal headaches will be avoided for sure. That was a very creative method for splitting the crankcase with the stuck powerhead bolts! Please be sure to remove the crankcase alignment taper pin first though, before the crankcase bolts, the case halves will then split easily with just a few raps on the crank with a heavy plastic mallet. Too bad this engine is a finished for sure, unless you can find a decent used powerhead...
Yes, having the exact right OEM tool definitely makes a lot of jobs easier, that's for sure. Unfortunately we are primarily an automotive shop so all the money goes into tools like spring compressors and radiator pressure testers that are no use at all on these outboards! As you say, second hand powerhead from a wrecker is probably the best way to get this motor up and running again.
I always treated the flywheel "puller" more like a tool to put tension on the flywheel. Put the tension on by hand so it's fairly snug then tap (pound?) on the flywheel. Little more tension and some oil-like spray and maybe a little heat and more tapping. Keep doing this a bit at a time rather than doing it all at once. Less chance of breaking a bolt and/or splaying out the center bold.
The "failures" are the ones you learn most from. Sadly enuff.
Great vid btw.
Keep up the good work!
Thanks mate. Yep, that sadly is the case.
just as an aside kiekaffer made very powerful outboards. i had 2 28horse engines. they had a spring relief deal instead of shear pins. the design flaw was the spring steel would chew up the aluminum housing and get sloppy. unrestricted the springs would slop and break. the fix was to machine the lower unit and sleeve it. pretty simple but never done . those 2 bladed buggers would go like hell. lots of good power heads. no lower units. oh well!
You the good the bad and the ugly things happen. Thank you learned a great deal from you have a great Christmas 🎄 Chris
love your videos brother. I learn so much watching them. Funny too!
Beer as a fire control system. Neat 🙂
This is why I'm thankful my boat is never in salt water!
You're a funny guy! I like your videos. They make me look smart on the water.
Glad you like them!
@@DangarMarine Wish I was there with you. I hear that the women to men ratio is 10 to 1
Stu is a sniper with that plasma cutter dam great tear down thx
Thanks mate!
The top of that piston was Joe Mangled it even had some rollers embedded in the piston.It reminds me of the USS Eldridge which had sailors embedded in the metal after the ship reappeared after having disappeared during the US Navy experiment on attempting to make a ship invisible.
I had the same image, a bit like that X-Files episode where people were embedded in solid objects.
Hahaha Best one yet Stu.. Loving the flare-up Not my words , but great man said today " that beer is known for its fire retardant qualities (being a mid strength) That Johnno is rooted for sure. Looking forward to the seized bolts episode
Thanks Mark, it is a good point about keeping some mild on hand for fires, don't want anything too strong!
Safety squint do the job just fine, where did you get the poster in the back left at 15:58?
Works every time. ;) It is a free calendar from our Wurth supplier.
nice, good stuff
Had an old duffer explain to me years ago to not use the puller to actually pull of the flywheel but to use it to put a strain on it and tap the flywheel with a non-metal hammer. Keep adding a little more strain (half a turn) and keep tapping on the wheel. A little lube and a little heat maybe but go slow with the puller.
That certainly is a good technique. Need to be careful with heat due to the wiring beneath the flywheel but it is amazing how often a relatively light tap will release something once it is under load.
I rebuilt a Johnson "Big Twin" 40hp (vintage, from the 1960s) and my first clue something was wrong was finding needle bearings lodged in the sparkplug, between the threaded housing and the ceramic insert containing the electrode. Was a real "holy sh!t" moment, considering I was riding in the boat not 5 minutes before finding the bearings lol
It's never a good sign...
@@DangarMarine No, but it was rather funny, looking back on it. Ended up getting it re-sleeved, replaced pistons, rods, everything. Used that engine for another couple years and sold it for a fair bit more than I paid for it. ;)
Edit: Sorry to hear about the hardstand issues, hoping to see more on the steel tub once it's up and dry, was what drew me to your channel. Best of luck Stu
my 2013 150 opti dropped a piston and the powerheads bolts were just as stubborn Stu..i gave them a good working over laterally with the air hammer and penetrol and managed to shake the corrosion loose..so much for factory corrosion control hey..Nice work anyway mate
You can't beat an air hammer!
man I love watching your videos every one of them are the best on youtube I sure wish I could meet you
We'll be having another channel meet up on the water this year if you are local to Sydney.
@@DangarMarine I'm in America I don't think I will be coming that direction any time soon
Great vid as usual...found my eyes drifting over to that calendar though I must say
Jason Fratantuono lol. I didn't notice...until you mentioned it. Then I couldn't stop staring either. Lol
Fireship1 Yea haha
Stay focussed! ;)
Nice work as always stu
Thanks Dean. :)
Thanks Stu, I'm having the same issues with a 1996 Evinrude 60hp. Think I will try take it apart , but not going to spend lots of money on parts . Will give it a crack!
It’s always worth a shot. If it frees up, great. If it doesn’t then you haven’t put any real money into it.
As usual great vid Stu.
Thanks John.
I have learned so much from your vidios I gnow ot an old outboard just to tear down myself, I will let you know how it goes
I had the same problem with my Johnson 25hp. I had two bolts stuck. I cut them the same way. The drive shaft was stuck also. I tied the power head to the back of my truck and tied the lower end to my house. I drove off and still had to beat it with a sledge. What a nightmare. This is usually all caused by poor maintenance. No water to the jacket. Change your water pump every season folks. In your case a bearing.
They sure can be hard to get apart once they get to that stage.
I guess that's what being a good mechanic is all about. How to overcome the myriad of unforeseen problems.
One thing you can count on when doing mechanical jobs is that nothing ever goes to plan! ;)
Informative and fun video. I like the attention to the beer. +1
Thanks Matt!
I wish you service my Mercury 90hp. Great channel, thank you.
Enjoy your videos and you are obviously a master mechanic. It was great seeing you do the "autopsy" on that engine and your technique and work for getting around the stuck bolts etc. But wouldn't it have been easier to put a fiber optic scope into cylinder and see the damage to the piston from the crankshaft bearings ?
Yep, I could have put the scope in and done a 30 second video but then I would have had to think of something else to film!
Just a thanx from Norway, love your videos👍🏼
You're welcome Raymond. :)
Well that was fun. thanks for the heads up dont what to have to do that one. peace and be safe.
Wow thanks for the reply for finding war year my motor is. Thanks again
Welcome. :)
Love your approach. Classic to see you pour the beer on!! Deadly :)
Thanks John!
love it when he starts heating it up with a beer in the other hand then decides to poor it on the flame
Using a beer to cool? That's alcohol abuse..!! Keep up the great work...!
Wore some over my street glasses yesterday drilling a dowel pin hole in a steel pin. drill bits can break and sometimes shatter. had a spring hit me in the face not long ago. didn't hurt but example stuff can fly so better safe than sorry.
It certainly can happen when you least expect it!
Hey Stu that was great take apart video!there is really nothing that can prevent this from happening???????
This boat had sunk and filled with mud so keeping it on the surface is probably a good way to prevent it from happening. :)
Nice video. I ask the same as Johan sundberg. Why do the bearing break?
Can be a variety of things, but this outboard had sunk in very muddy salt water about six months ago. Combine that with being almost 20 years old and used every day...
Wow, what a job!
Great video! What is the likeliest reason for the bearing failing? No oil, overheating or just à monday?part ?
Can be a variety of things, but this outboard had sunk in very muddy salt water about six months ago. Combine that with being almost 20 years old and used every day...
Hey Dangar, for rounded bolts try Kincrome lok on bolts, theyre pretty good
Sockets*
Stu, did you see how close that bolt or ? came to hitting your eye? You might want to think about safety glasses mate.
Great video! One thing is for sure whether down under or in the States tough jobs require a beer in your tool box.
It may have looked close on camera but in Matrix bullet time I saw it coming for about 4 minutes. Dodging was easy. ;)
Dangar Marine Haha, well at least you were wearing your safety condom on the one hand, I mean you could easily do with one eye but how you going to work if you can't hold a beer and a screwdriver at the same time?
Your videos are great.
Thanks mate. :)
Oh man. I thought you were going to throw a couple of snags on the oxy baryby for a moment their... I know the feeling... I worked with and on motors and adjoining bits for twenty years in my own business and this reminds of why I never want to go back. Wouldn't be so bad if there weren't bills to pay. And don't worry bout cross faces. I had them, plus cross words plus cross flying things from tools to well anything ... it's a tough gig. But nothing a day on the water with a few coldies won't fix. You did well! coltrump🇳🇿👍🏻👍🏻👍🏻
Another effective method for freeing stuck driveshafts on the 2/3cylinder OMCs with exposed upper driveshafts is to attack the upper driveshaft under the powerhead with an air hammer while an assistant gently pries down on the gearcase. The best way to avoid this situation is proper maintenance to begin with. Salt water engines should have the gearcase removed every couple of years so the splines can be cleaned and relubed with OMC moly lube. Needless to say, the impeller should be changed while the gearcase is off as well. As a OMC rep, I was continually frustrated by techs who skipped over this important step when doing water pump jobs, especially on salt water engines...
For sure. The gearboxes come off all the outboards we service at least once a year for an impeller inspection / replacement and cleaning the old grease out from the splines then adding new is definitely something we do as we know we are likely to be the next people who have to take it off!
hi Stu this video is very informative even more so because I have a 50hp Johnson but mine seems to be fine so far no problems with it at all
what I'm wondering is if any of the parts off this motor would still be useable & would you part it out
in particular starter motor set up & Power trim / Tilt set up as my outboard is Manual start & manual tilt
would hate to think they were just thrown out not that I think you would if they were of any use
thanks for the work you put into the videos for our entertainment
Yep, when motors like this die I always strip all the useable parts off it and store them away.
Hi Stu, excellent video. I have a Yamaha 15 2 stroke where the main bearing failed. Is there a way to remove the centre bearing? How do you split the crank. Not sure if it’s worth repairing but I like to have a go just for the craic. Any help would be greatly appreciated. Thanks
Thanks Lorcan. Unfortunately I don't think you can replace that centre bearing. I spent ages trying to find an angle I got get a shot at pressing the crank apart but no luck. Next time I was at Yamaha I asked about it because I thought it was odd and they said no go, whole thing needs to be replaced.
Thanks for you help keep up the good work with the videos.
Great informative video mate
Thanks Steve!
Learned a lot about perseverance. What good parts will you save? Do the bolts and screws go in a coffee can, or are you super organized with lots of little bins and drawers? There is a mechanic in my town with a collection of a 100+ complete engines, some running... for parts.
Quite a lot got saved off this outboard. I don't keep the midsection due to lack of room, but the gearbox and all the smaller parts that got taken off the powerhead get stored. My bolt box is just a jumble though. The only way I divide them up is metric and non metric.
Interesting, thx.
Well the motor caught on fire let's pour a beer on it oh well that didn't work back to the heat. Buddy the things you do are great
Oh well, if you can't get it out just push on!
Cool video. Good to know information. Thanks
Thanks mate.
sorry to see you suffer the loss of brown bottle contents.Keep more towels close ready for next fire and save the refreshment!!!
Hello I am looking for a tear down and rebuild of a 1996 Johnson 200 HP Ocean Runner video or book. I would like to rebuild my Johnson outboard. Any information would be great! Love your videos! Thanks
thank you for the vid. I have a 96 evinrude 40. Can you put one of those onboard battery chargers you installed a little while ago on this type of motor?
Yep, sure can. If you take a look on MarineEngine.com you will be able to find the regulator rectifier that goes with your motor and order is separately.
thank you.
Hi. I wonder if you could please make a video. Of how to start a outboard motor on a stand ? I recently bought a 1998 ish mercury black max 150 hp. I have it on a stand but not sure how to start it . It's the electrical i'm not sure of. Or maybe you could explain it to me on this post . Either way it would be greatly appreciated
Hi Tom, that would be a good video. I normally just connect the forward controls to the outboard and turn the key as normal, but if you don't have that you can make a remote starter like this ruclips.net/video/LZGnKldqDsA/видео.html
Can you please add a link to your sponsors in your description. I enjoy your videos. I am a novice boat owner.
I'm not sure if I can add a clickable link, I'll look into that. The URL is the same as the name though, marineengine.com
Dangar Marine thanks
Excellent video mate! You just solved my issues with my motor xD
Pouring a kettle of hot water can work really well instead of using a flame. Lots of energy in a few litres of boiling water its surprising what it can do.
Hi Stu, longtime watcher. I have a mercury seapro 25 that runs for a minute and locks up, can be restarted but repeats. Appearently they dont like running on the throttle stop for 30 mins constant. The motor cost me chips, is running a richer mix and a hotter plug a viable option? Do you have any suggestions. Cheers mate! Matt, Newcastle. NSW
Hi Matt, when you say it locks up does it stall or actually seize? If it seizes it sounds like it is an oil or cooling water problem.
Dangar Marine thank you so much for your reply and the great video.
Dangar Marine . Hi again Stu thanks for the reply, when it stalls the flywheel does still turn freely as could be re started. A water pump sounds like a good place to start as im unsure of its history and i know she had been out of the water for a few years. Kind regards . Matt
Love the channel, I know how long that editing can take. Next time put a borescope in through spark plugs and have a look at the top of the Piston, might save yourself a teardown. I got a cheap $20 that hooks up to your smartphone, 7mm tip with LEDs in it. They have them in whatever length you need
We've got a good Snap On borescope in the workshop but I really just wanted to pull this one apart for the sake of making the video.
This story is sort of proof that despite the skill of the surgeon, not every patient can be saved. It's unfortunate, but I do concur with your assessment that it would be more money than it's worth. How long would you guess this motor had run (pounding pieces between piston and head) before quitting?
The owner reported that it had been running rough the day before and then seized. The average trip to the mainland is only 10-15 minutes so I would say 30 minutes at most.
Stan, I agree. And there are some people that I am sure surgeons would cut their monetary losses on if the person was on the table as well.
I know have their oath , but it really should be called the Stop correcting "hypocrite" oath for a lot of them!
i have got a recondition 350 chev i am putting back in my boat but am looking at putting a outboard on instead .It may be more economical but the thought of seized bolt puts me off somewhat
when useing the puller i screw it down with a fair amount of pressure then put a socket on the end of it and hit wiyh hammer ive done it for years
Good technique. An impact shock can do wonders to free up a part once it has a bit of load on it.
Did you try beer on the threads and crankcase?
I really enjoyed this video Stu! Thanks for the content. Rumor has it these old Johnrudes are known for bearing failures. If the bolts wouldn't have given you any trouble, how many hours do you think it takes to strip, rebuild, and reassemble a 6cyl Johnson like the one you have here?
Good question, I'd say it would cost about $2000 in engineering and pistons and then about 8 hours of labour on top of that.
Great video here, this helps me understand these motors better.
I have an '80-something 60HP Johnson 2 stroke that died yesterday. Running nice and smooth around 2k rpm then it stopped quickly. It had run nicely last year, but this was the 2nd outing this year. Upon manually turning the flywheel I discover quite a bit of grinding when turning in the running direction, but no grinding in the other direction. Of course it is in neutral. I can turn it 360 degrees, and like I say it turns freely in the reverse direction. Nothing getting jammed under the flywheel, which is off now. Because it turns without grinding in the reverse direction, I'm thinking it's not bearings. Am I crazy for thinking this is worth taking the lower off, then the power head to see if it then spins freely in the other direction? Maybe peek in through the reed valves with a scope. I think the motor has just been in freshwater, so bolts haven't given me too much grief...jinx. It also will idle intermittently until it abruptly stops. Tried that 3 times now before discovering my grinding. I'm thinking, hoping something might be just binding the driveshaft???? IMO if it's bearings I will feel grinding in both directions.