Rebuilding a 225 Venom

[302w]

Model # J225STLECS

Serial # G04358890

Alright ladies, I got a friend with a 1998 225 Venom with a down cylinder. 5 holes were showing 100 psi and top port cylinder was at "ZERO"

Just by looking at it, it looks like it had a bad head gasket allowing water to leak into that cylinder. Has anybody heard of this? My friend decided he wants to do a complete rebuild so I am wondering where you can get a factory service manual for it? I already looked at Evinrude's website and this model didn't turn up. I rebuilt my 150 mercury but what I want to know what are the major difference between the two brands? Thanks


Modified by 302w at 7:29 PM 4/11/2009

[ChampioNman]

One is black the other is charcoal gray. The Merc is 180* out of the OMC motor the components are on opposite sides, blocks are much different in that the OMC is a 90* block and the Merc is a 70* or something like that. Mechanical repair concepts are basically the same. Pistons and rods connected to a crank shaft goes up and down. You should still be able to get a manual from a BRP dealer, it won't say Venom on it but it will cover V4's and V6's of that model year all Big Bore loopers. The Eagle line is for the 60* motors. Yep have heard of head gaskets going bad letting water in, your buddy is right on wanting to do a rebuild. Good luck.

[302w]

How heavy is the power head after I get all of the linkage's ad electronics off?

[Bassmeister]

450 with everything on it.

[ChampioNman]

the linkages and electronic don't weigh a thing. Starter 15 lbs. You have to remove 8 bolts and 3 nuts to pull the head. Pull it off with the lift ring and put it on a roll around. About 325-350 then. Two pretty strong guys can lift it onto the bench if you put a pipe through the ring and clamp either side with vice grip pliers.

[302w]

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by ChampioNman &raquo;</TD></TR><TR><TD CLASS="quote">the linkages and electronic don't weigh a thing. Starter 15 lbs. You have to remove 8 bolts and 3 nuts to pull the head. Pull it off with the lift ring and put it on a roll around. About 325-350 then. Two pretty strong guys can lift it onto the bench if you put a pipe through the ring and clamp either side with vice grip pliers. </TD></TR></TABLE>

The dam power head weighs 350 lbs?! Chit, would I be able to pick it up if I took the heads off and the carburators/reeds off?

[ChampioNman]

The crank weighs the most.

[302w]

Alright Champ, got another question. What is this part?

049
Split Sleeve Race
Split sleeve outer race fitting V4, V6 and V8 crossflow and looper engines.
$66.59

[clayshooter]

I don't know the exact weight,but if you strip it down to the bare block and crank/rods/pistons.I would thing 1 man could lift it off.
I did my 175 Ficht in that manner.It was not real light,but it was managable.
Had a place to set it down on a stand setting right beside the motors mid section.
Worked for me,as I did not have any head room above the motor to work a lift or come along or such.

Ed

[302w]

Yeah it seems like i am going to have to tear it down to lift it up.

Champ or Seahorse, what is the stock bore size, gonna try to get the block to the machine shop on sat.

[ChampioNman]

You better try and pop it off before you start, I've had a few that wouldn't come off and took some real work. That number is no good Robert but it sounds like a main crank bearing (in the block). 3.685 is standard bore.

[302w]

Alright guys, got an update for ya. Took the heads off and top port piston definitely took a dump. Part of the piston broke and the rings broke embedding itself into the head as well.

Champ or seahorse, there is a little hole towards the exhaust side on the sleeve and a piece of piston got stuck in there. As long as there is no hole in the block this can be fixed by a machine shop right?

Also, what type of socket do I need to get the flywheel nut off? We tried every standard size from 1 inch up to 1.5 inch. None of them worked? Do we need a thin walled socket or what?

One more thing, can any of you give me some history on this motor? Thanks


Modified by 302w at 9:30 PM 4/5/2009

[302w]

bump

[ChampioNman]

1-7/16" Impact socket is what I use. Only history on the motor would be for the 1 year it was under warranty and that would only be for claims filed. Sound like it caught the finger port. Standard bore is 3.685 and you can go up to .030 oversize. If it is too bad you'll have to have it sleeved and then stick with the stock size piston and ring set. Either way way when you order the piston set you'll get everything you need except the needle bearings for the wrist pin you'll have to order them separate. You can get the sleeve from Pro-marine USA. Sounds like you'll need a new head also.

[302w]

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by ChampioNman &raquo;</TD></TR><TR><TD CLASS="quote">1-7/16" Impact socket is what I use. Only history on the motor would be for the 1 year it was under warranty and that would only be for claims filed. Sound like it caught the finger port. Standard bore is 3.685 and you can go up to .030 oversize. If it is too bad you'll have to have it sleeved and then stick with the stock size piston and ring set. Either way way when you order the piston set you'll get everything you need except the needle bearings for the wrist pin you'll have to order them separate. You can get the sleeve from Pro-marine USA. Sounds like you'll need a new head also. </TD></TR></TABLE>

Thanks champ, as for the heads, I told him that he have them shaved for $230 as opposed to buying new ones at $380 a piece.

[302w]

--------------UPdate--------------------

Got the carbs and the electronics off the power head and got the power head off the mid section.

Champ or Seahorse, what is the deal with the carburetors on this motor? We had hell trying to get them off. We ended up having to take the little black looking rounds things off the front and then we were able to get the front half off. Are there 6 carburetors on this motor? I heard there were only 4 on it.

[ChampioNman]

If you took the hoses off the port side carbs you wouldn't have had any trouble. There are 6 carbs on the motor or it would be a V-4.

[302w]

UPDATE: We got the motor torn all the way down now I need to know how to get the bottom main bearing and end cap off. It looks like it's pressed on there.

[mochuck]

my 200 vindicator #1 piston looks just like yours,fixed mine with $16,500 check

[ChampioNman]

PB blaster and a two jaw puller. If it ain't bad then don't mess with it.