200 hp Evinrude Rebuild

[olnsnz]

WASSUP EVERYONE. I AM NEW TO THE FORUMS & I WAS LOOKING FOR SOME ADVICE. I HAVE A 1981 EVINRUDE 200HP THAT LOST COMPRESSION ON 1 CYLINDER. THE 5 CYLINDERS ARE TESTED @ 110 - 100 LBS AND THE LAST ONE WAS 80 LBS. I OPENED IT UP AND LOST A RING. THE PISTONS ARE 30 OVER AND WAS WONDERING IF I GO 40 OR 60 OVER WILL THIS MOTOR BE RELIABLE? I USE MY BOAT EVERY WEEKEND TO GO CRUISING OUT AT THE SANDBAR. sHOULD I CONTINUE THE REBUILD???? ANY ADVICE/OPINIONS WOULD BE HELPFULL!
ALOHA FROM HAWAII

[phil blomquist]

Id say depends if you got the funds for a newer one but 40 over isnt going to change the reliability of the motor,lots of people on here running 40s rebuilds cost a heck of a lot less just my .02 worth good luck phil:leaving:

[olnsnz]

THNX PHIL! Kinda like a budget build so yeah im guess im gonna rebuild this one. The motor was running fine untill it lost the cylinder...

[phil blomquist]

welcome to s n f lots of people on here to help you with all the answers .:thumbsup:phil

[olnsnz]

How much do you think it cost parts & labor for the complete rebuild? Thnx lmk

[phil blomquist]

kind of a loaded question how much?pistons 100.00ea replace one or all? gasket set 100.00.machine work maybe 200.boringone holecleaning others misc parts who knows? go online to pro marine.com and price the parts dont know what kinda dealersyou got on the islands but there are lots of guys on here that will take care of you for parts also machine work etc, be carefull buying parts if your not doing the rebuild alot of mechs dont install customer parts so ask first.If your doing it get ur done aloha phil:D

[wideglide55]

Make sure you have the carbs gone through,pay special attention to the one on the cylinder you lost,always run premium fuel and a fuel separator on a crossflow and make sure that your timing is no more than 25degrees.
Regular gas make crossflow go boom.

[EMDSAPMGR]

Have you measured the cyl walls to determine if you need to overbore it? Was the low compression cylinder liner wall damaged when the ring let go? You can bore just one cyl.

[olnsnz]

I looked on a couple websites for complete engine rebuild kit and average price was around 1200 shipping (hawaii) not included. Also wanted to know what kind of oil you guys recomend for pre mix and what ratio I should use. What would cause the ring to go on that cylinder? Could it be from using cheap oil and running 87 octane?

[olnsnz]

yeah the one cylinder that lost the ring has some marks in it but not to bad. I am doing all the cylinders rather than just one because we gotta tear it apart anyways so may as well do em all so i can have a fresh motor.

[wideglide55]

Yes on both counts,old crossflow + regular gas+cheap oil=what you have now.Run Merc premium plus oil at 50/1 for normal use,40/1 if you run hard.Older crossflow motors don't like regular unless they have been set up to run on it. Also if the timimg is set up to like 28 or 30degrees, the first load of fuel without enough octane +a good burst of full throttle=go buy more pistons etc.I would rebuild it with the thicker style head gaskets to drop compression a little,since the 10percent alcohol fuel is so crappy.Also dont overlook replacing all fuel lines,including all the molded ones.I wouldn't be surprised if the main jet on the hurt cylinder has a chunk of rubber in it from a deteriorated fuel line.Had it happen to me after six new pistons and 1.5 hrs run time.

[gmacrae]

For the money you're thinking about spending on yours, can you pick up a tired later model motor and give it a freshen up? (hone, rings, impeller, gaskets, reeds etc). You'd probably end up with a better engine, and still have yours to sell as parts?

[wideglide55]

bnjackson5 on here has a 150gt powerhead that runs good for $495.00 in outboard motors for sale.

[roadkill636]

I got a 1976 200 block that I had all 6 bored 30 over and never did anything more to it, just sitting on the shelf with the cyls protective coted of corse, anyone wants it $50. come and get it. needs new threads on one starter bolt hole. pm me for more info

[EMDSAPMGR]

Your 200 block is a high port block as opposed to the 150 blocks-which are not. You would gain holeshot with a 150 powerhead, but lose a couple hundred rpm on top. The 76 200 is a probably a high port, but does have a different shifter mechanism on the front end which may not match your midsection shifter linkage. Factory pistons go up to .030 over-above that, you are looking at aftermarket pistons.