Finally got my '92 Johnson 115 V4 apart. I'm no expert at all... in fact this is my first time to pull an engine completely apart like this. But it looks like everything is in great shape except for the one piston and one Cylinder.

My next step is: I'm going to take it to a machine shop and have them bore and hone the bad cylinder and put it a new piston with oversized rings. Does that sound right to ya'll.

While I'm at it i'll soak the carbs to make sure this doesn't happen again.

Am I leaving something out? This almost seems to easy??
Anything else I need to do?
Like I said this my first time so any info or advice is greatly appreciated!!











Thanks

Machine shop will tell you how much boring is needed & what size piston to get. They'll also measure the others for wear & out-of-round - might need more than one oversize. All 4 will need honing, think about having them do that also. And get the head machined. Make sure it's a marine shop not strictly automotive. They should be able to give you the specific measurements.

Follow the manual step by step, torque everything by the book. Some real good expert advice here:
http://forums.iboats.com/forumdisplay.php?s=&daysprune=-1&f=24

Kinda takes the mystery out of it, eh?

A word to the wise. Do all four oversized. It will end up costing less in the long run. NEVER NEVER put a new piston in an old hole or re-ring and old piston in an old hole. Just my .02 cents//
Also the rubber tube between the cylinders,(water diverter tube), Replace it, and not with fuel line, Use the right stuff.
Also just by looking at the other piston, the oiler rings are wore out, skirt skuffing is present, bottom line the piston is wore out.
Also, Check the heads for warpage, If a head is warped more than .015, Replace it. 2 strokes don't like their heads milled to much unless your modifying carbs, timeing etc. Your changing the dynamics of the engine by milling a head, which bumps compression, which makes the reeds operate at a different time, which changes the timing of intake and exhaust, which in essence changes the engine engineering of the engine.

Tha main thing thing not mentioned yet is "CLEAN". Wash n dry everything and when ya think ya got it done wash it again. Especially tha block. Anything tha machine shop touches. Then ya can put a oil and/or oil n gas mix on everything. Keep your table covered and "CLEAN".........T

Thanks for all the info, So far... good stuff.

I just gave Dwayne a call in Grand Prairie, and I'm gonna take it to him later today probably.

It just occurred to me though that I''m gonna need new gaskets on almost everything. And a couple of Carb kits as well.

Mike, love your advice but that has got to be the the best triple usage of engine in the same sentence!

You'll need the whole gasket set and some OMC sealer...(I forgot the name of the red stuff that goes in non-gasket surfaces). You'll also need another OMC product...for the gaskets. ( another name I forgot....Triple something??) Just ask the dealer or look in the OMC service manual.

I hope you marked those rods...to put them back on the same crank lobes they came off of. ( sorry if that insults you, it wasnt meant to)

Have fun with it ! I always enjoy working on mine....(after fishing season ends.)

Yea it kind of snowballs into a cluster smuck.