It's dead, Mammy! It's dead!

[SkeeterStew]

there is a way to take care of all those oil injection hoses... eliminate the whole oil injection system, build a plate to fit over the oil pump on the block and get rid of all the tanks and wiring harness for them and just do a premix.. thats what I ended up doing... I wish you the best of luck ... and I'mwatching this, because I might be there some day.... We are doing the same thing to a buddy of mine's 200 johnson. just has some small differences... but pretty much the same.

Good tip, Needs2hunt (and great username haha!)

Everyone says that this oil injection system is almost foolproof so I think I'll put it back together and run it like it was from the factory. I will be using premium gas in ol' nemo now though. And I'll be premixing 25:1 just for safety's sake. The reason it failed is because the PO (previous owner) let it run out of oil entirely and when he went to check the oil fill on the engine he busted the sensor off so he let it run out again. Genius, huh?

Now for some more good news. You guys are awesome people. I couldn't have picked a better site to start this build on, lemme tell you! One of the members saw my thread, PM'd me, and donated $250.00 to the project. WOW!!!!! Just out of the blue! "Take them kids fishin and post a pic of the fun" was the only requirement. I think I can handle that! Thank you!!

So Ol' nemo will go into the shop TODAY to get re-sleeved. Then it's off to the races, putting him back together. Hopefully I can do it right. I don't want to have to do this again any time soon haha! Thanks for watching guys. It's about to get buttoned up!

[Charlie206]

Awesome. Do you have a torque wrench? It is an absolute 100% necessity before you start building.

[SkeeterStew]

Awesome. Do you have a torque wrench? It is an absolute 100% necessity before you start building.

I do have a torque wrench! I needed it for fiddling with my old truck a couple of years ago. I always "generally" calibrate it too before every torque session to make sure it's working. I had one from Harbor Freight that went out on me and I ended up snapping a bolt off. That taught me a lesson!


Little update: I dropped the block off today. He said it should be done by tomorrow evening. Now that's service!

[Charlie206]

Great. Follow the manual carefully on the reassembly. Ask questions here where needed. Everything must be CLEAN. You will need a ring squeezer, auto parts stores have them cheap. The rings can be installed by fingernails, but it is not at all fun. Cut open a big trash bag or use a piece of plastic sheeting to wrap up your work product when you finish each day to keep dust, bugs etc out of the block. Be careful cleaning up the gasket surfaces, it's all aluminum and you can't treat it like steel when cleaning all that crud off. Let us know what you need. Don't forget, there are port pistons and starboard pistons, you can't mix them up. Take your time, go slowly, double checking everything. You can do this!!!!!

[SkeeterStew]

OK Charlie, here's one for ya. I put the crank in and laid the intake over the top of it to see how it fit. And it was about 1/8 inch up in the air. Is that just because of the rings on the crank pushing it up or should it lay down flat?

[SkeeterStew]

Today's fun started off with a broken pipe nipple. A "Purple Nurple" if you will haha.

Part number 6E5-11372-00-00 that goes on the bottom of the intake. It's this thing sticking out the top of this picture that looks like a fire plug..

$_35.JPG



Item ordered for 7 bucks. I'll have it in a few days.

[Champ203]

Great job. Love keeping up with your progress.

Special thanks to the person who helped make this possible financially - I'm sure you are still following this thread.

BBC is a special place.

Peace,
Don<><

[cwilt]

Congrats on your rebuild. Won't be long now and she will be purring down the lake!

[javelin90]

Good job!

[BoatBuggy]

Looking good SkeeterStew!!!!!

Special thanks to the person who helped make this possible financially - I'm sure you are still following this thread.

Indeed.....

[SkeeterStew]

Great job. Love keeping up with your progress.

Special thanks to the person who helped make this possible financially - I'm sure you are still following this thread.

BBC is a special place.

Peace,
Don<><

That's the truth! I've never seen such a thing and I've been on BBs since the 90's. You could have knocked me over with a feather. The thing weighing on me now is how to pay it forward in the future.

Congrats on your rebuild. Won't be long now and she will be purring down the lake!

The kids are bouncing all over the place hoping I'll get it done pretty quick. I have to admit, I'm kinda pumped too. This anaerobic sealer is kinda a bummer, but it'll fix. More on that in a minute.

Good job!

Thanks Javelin90!

Looking good SkeeterStew!!!!!

Thanks BoatBuggy! Maybe I'll try to figure out how to fix gelcoat damage after that. Anyone interested in a writeup on that?









So this anaerobic sealer is a pain in the hindquarters. The humidity is the problem I think. It's 91% as I write this. The anaerobic sealer is still gooey just like when I pushed it out of the tube - and it's been three days! I'll wait until it's gummy and dry to the touch before I continue so I don't mess anything up. I will tell you guys this, I put the flywheel nut on the end and gave it a few spins to make sure everything was kosher. It spun soooo smooth and nice. Like buttah!

[Charlie206]

Don't worry about the sealer. It dries in the absence of atmosphere in thin layers. So the stuff that got forced out will remain wet outside of the block, just wipe all that off. The stuff squeezed in between the block flanges is ready to go, as it is very thin and there is no atmosphere there. You put a bit too much on there but once you torque the block together, hopefully it's all good.

[cwilt]

Don't worry about the sealer. It dries in the absence of atmosphere in thin layers. So the stuff that got forced out will remain wet outside of the block, just wipe all that off. The stuff squeezed in between the block flanges is ready to go, as it is very thin and there is no atmosphere there. You put a bit too much on there but once you torque the block together, hopefully it's all good.

In other words keep pressing on. It will dry when torqued.

[Charlie206]

Yep. Get back to work, time is wasting.

[SkeeterStew]

Haha, I haven't been entirely slacking. I put the back water case thingy back on yesterday and torqued them all down to 5.8 ft-lbs. 20 some odd bolts in that thing. The old gasket was fun to get off too. I think it had metal in it! I didn't photo this since I shouldn't have removed it anyway. I was just looking for a way into the exhaust and thought I'd go ahead and change the gasket while I had it apart.

Anyway, that's done. I do have a question though. The reed assembly is my next step. I think. I was checking the little pop-up pieces and some of them make an audible "pop" when pressed open (presumably to allow fuel and air in) but some don't make any noise. They aren't stuck or anything, but they don't "pop" open. They just open. Is that OK?



Also I ordered 2 new fuel pump diaphragms. I was told to get those changed while I was elbow deep in it. For 14 bucks I guess that's OK.

[Charlie206]

If the reeds appear to fully close and seat, you're good. Changing them out is more bucks out of the budget and it ran fine before it blew.....

[javelin90]

Continued progress
your getting closer everyday!

[headhigh]

You're doing great! Keep it up. And GOD bless your secret donor.

[Charlie206]

Refer back to post #12 on this thread. Where are your PICTURES?

[SkeeterStew]

Haha, Charlie! The ports (I think) were wired up wrong since there are no references in my Yamaha manual that showed it ported like it was when I took it apart. I could just route the hoses back that way, but I think it's wrong. Post #79 shows alot of the previous routing. For instance, some of the previous "fuel puddle" lines went to the oil pump. That makes no sense. I'm not sure what the "fuel puddle" system is, but it seems to feed excess pressure and maybe gas back to the carburetor. Or maybe vice versa. It doesn't have a directional arrow on the hoses

Feeding oil into this system sounds like a problem. What do you think?