96 Johnson Venom 200 hp what is the bore size? and where can i find a sleeve?

[khamrick55]

Hello ... i have a 96 johnson 200 motor which has broken a ring has a groove deeper than .040... need to know what the bore size is. any other ideas would be helpful. thanks

[tvd]

Standard bore size is 3.685 inches. Sleeves available at Advanced Sleeve in LA area. I did #6 on one of my blocks, and it cost roughly $350 with the sleeve and machining. Honing the other five was included. Best to get a MARINE qualified machine shop. They know how to fit the pistons.


EDIT:
OOps....Advanced Sleeve is in Ohio, LA Sleeve is in LA.

[khamrick55]

Thanks for info...was looking at some sights and comming up with 3.5995 ...whats the deal with fitting the pistons? do ring ends have to be in a certain place? like away from ports or something else?

[phil blomquist]

best to get factory manual for your specific model so you can take all the guess work out of it best money spent

[tvd]

Thanks for info...was looking at some sights and comming up with 3.5995 ...whats the deal with fitting the pistons? do ring ends have to be in a certain place? like away from ports or something else?

Cannot comment on the 3.5995 figure. Probably the small bore 200 from earlier years...1987 or so...not sure. BUT, I know your engine has 3.685 STD bore spec. Ring ends are located by a small pin pressed into the ring groove of the piston. The rings cannot rotate if all is well. But, the locator pin can come out and make the groove you have right now. When you have it apart, match up the groove with the location of the ring locator pin. You may also have a chip in one of the ports....
Pistons are assembled correctly ONLY ONE WAY. If they are reversed or upside down, they are in wrong. The rod must be assembled only one way also. Oil hole in the small end of the rod faces UP.

The pistons are different between the stbd and port sides of the engine. They should have a "P" or an "S" as part of the part number, or the word "port" or "stbd" stamped on the top.

Correct me if I am wrong guys, but usually the shop bores the old sleeve out, then fits a new one, pressing the sleeve in cold, with a heated block. I think that is the way they do it.
Consult a machine shop that knows marine engines.

[khamrick55]

thanks much

[Wingnut0302]

Did you happen to just buy this from a guy in PA?

[khamrick55]

no..is there one up there with the same problem?

[Wingnut0302]

There was one near maple grove raceway for sale that had a bad hole and I was just wondering if you happened to grab it

[racer]

If the sleeve is not damage the old one is removed by heating the block to 425 degrees for 45 minutes and it will fall out, make sure to retain the others so they dont move. If damaged you cut the sleeve length wise and it will come out but you have to be very careful not to cut aluminum. The cross flow blocks they have to be machined out. If you have a new sleeve ready you can reinstall while the block is hot but make sure its lined up. Then it can be bored to size.