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  1. #1
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    Evinrude 225 HO Should I cut my losses

    Hey guys new to this site but not to forums. I bought a used boat last year and within a month windowed the block. I had a complete rebuild and motor would idle poorly during break-in and continued after. I decarbed, replaced plugs 4-5 times threw obscene number of parts at it including coils, wires, tcs sensor, crank sensor and babied it throughout the season. I even took it to a BRP Evinrude dealer and paid them to look at it and it had them stumped. All 6 cylinders were loading the plugs and the miss at idle couldn't be isolated. Drop tests during runs couldn't isolate it either. after 30 hours I finally found the pulse hose to the lift pump on 5 or 6 was leaking due to bad diaphragm and would build up fuel thus filling crankcase with raw fuel. After fixing it the problem went away and boat ran great for 5 hours during half dozen tournaments. Running back from fun fishing motor stumbled and I knew I was down a cylinder. I limped it to ramp and when I got home I found the sparkplug on 6 had been contacted and was closed and compression at 87 lbs. I used scope and the piston is missing a piece right at the exhaust port. Pulled the head and there is a scuffed groove in the cylinder not massive but enough to click your fingernails but not hang on. I have no idea if the piece went out exhaust or into crankcase etc. The rest of the cylinders are still at 118-120. If I put a piston in it will it be ok or is this a grenade? Does it need a hone? Bore? I'm still paying for the rebuild and I have lien on boat and motor which I'm upside down at this point. I'm looking for guidance as I'm in tough spot and don't want to make a knee jerk reaction. Can I contact lender to release title and part it out? I'm back to the same point I was last winter. Motor is a 2004 BRP 225 HO.

  2. #2
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    Can you post a pic of cylinder and piston? A leaking pump should have been found by the dealer as thats not a tough check.

  3. #3
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  4. #4
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  5. #5
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    Quote Originally Posted by racer View Post
    Can you post a pic of cylinder and piston? A leaking pump should have been found by the dealer as thats not a tough check.
    The leak was very small a drip every 5 seconds if you pump the bulb. But it would build up in the hose once sitting.

  6. #6
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    The pump is an easy test with a psi or vac gauge on the pulse hose. It looks very lean so I would be concerned about that injector especially if thats the cyl. it hurt before. How was the cyl honed as the first pic shows that it might be out of round.

  7. #7
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    This wasn't the cylinder that failed before. This was a fresh machined block as it trashed the old one. I'm going to mic the cylinder. The injector passed the static testing and drop test. This was the cylinder closest to the pulse hose that was dumping fuel. It's surmised the cylinder had washed out.

  8. #8
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    Kinda hard to see in the pic's but doesn't look like the ports have much of chamfer on the top. Also does look lean.

    Dave
    1980 Cougar 19 tunnel,90 2.4L Bridgeport EFI in middle of restoration.
    1988 BAJA Sunsport 186, 96 225 Pro Max
    79 12' Auminum, 95 Merc 9.9
    RIP Stu
    "So many idiots, so few bullets"

  9. #9
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    Dark color below your finger and across from exhaust port looks like ring was not touching or is it rust? If rust you may have had a leaking head gasket causing it to steam the piston. Assuming you had injectors matched to emm and correct location. Was timing set? Break-in? Was assembly and machine work done by same people?

  10. #10
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ID:	332471You can see the chamfer in some of my other photos. I will check the cylinder with bore mic tomorrow and hope it's a hone and piston.

  11. #11
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    Machining was done by builder in-house. Break-in was started during hours of testing by builder and completed by myself strictly by the book. The one concern was that the cylinder was washing out due to leaking lift pump from get-go. Head gasket seemed ok and I had checked torque on the head bolts during entire ordeal. Some of buildup may have been idling boat back to ramp with spark plug closed and/or dirty hands during head removal.

  12. #12
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ID:	332472Now that you mention it there is a line on the cylinder discolored. This is the top side inverted picture.
    Last edited by Stratos_Kid; 11-30-2015 at 05:09 PM. Reason: cylinder

  13. #13
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    Quote Originally Posted by Stratos_Kid View Post
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ID:	332471You can see the chamfer in some of my other photos. I will check the cylinder with bore mic tomorrow and hope it's a hone and piston.
    Al, (racer) check the top of the bore in this picture. Looks dry to me.
    I agree in the lean look to the pocket on the piston dome as well. A leaking head gasket could do this, no? From the steam??
    I chased this for a while on my hot rod 3.3 before finding it. My block had a machining error that allowed the sleeve to push bellow the deck surface when torqueing the head bolts and caused the head gaskets to leak under pressure.
    Could see it when putting a straight edge on the deck surface.
    I'd rather be competitive w/junk I built in my garage than win w/stuff I bought.


    I refuse to allow common sense to interfere w/my boat buying decisions.


    Checkmate 16' 140 Johnson
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  14. #14
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    That goes well beyond my expertise. I doubt it would have lasted 35 hours with leaking
    head gasket though would it? I'm just trying to
    make this motor right and dependable.

  15. #15
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    Yes Gary bores look bad at top and have several discolored areas that would concern me. Looks to have minimal cross hatch as well. I would be checking bore top to bottom to make sure it is straight and round. Do NOT hone with any thing other than a good sunnen type hone with key way stones if possible.

    Looking at your bore it appears top ring was not on the bores near the top which may indicate an issue with bore or ring not free in piston. This could have been why the piston has a piece missing at exhaust port and why it started to burn. I would still be concerned cylinder is lean either from injector or water intrusion. The leaking pump did not cause this issue.

    Yes it could have lasted with the leaking gasket especially with leaking pump adding a bit of fuel. It only takes a VERY small water leak.

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