OK, my second attempt at posting…. Don’t know if it is my laptop or this site…
Like Bill says, disassembling most of these engines will reveal some minor flaws. Kind of hard to judge yours without seeing pictures. The beauty of these engines is that they run just fine even with some minor flaws. But, yours is apart now, so I’m guessing you want to make as close to perfect as possible. I’m confused about just what happened here though. Is this engine new to you? Was it seized? Why were you attempting to remove the upper seal?
In any event, you have to be careful when honing, because you are actually boring the cylinders just a bit. Over honing to get rid of all the perfections can easily lead to an oversize bore. You should take the time to measure the bores carefully before proceeding. Check them for out of round and oversize conditions. That being said, this is difficult to do accurately without good measuring tools and the ability to use/read them properly. I would invest in the proper OEM manual for this engine, they are out there, not too tough to find. I would avoid those generic manuals that try to cover many different years/models, they are confusing and can be inaccurate.
OMC originally sealed these crankcase halves with the OMC type M/847 sealer. This stuff works great but is tough to apply neatly and dries very quickly. OMC came out with their anerobic sealer “Gel Seal” in the late 70s, this can be used instead of the type M/847. It is easier to apply, and like the term says, doesn’t really dry until the air is removed/crankcase halves assembled. But, proper prep is extremely important, or this stuff won’t seal properly and the crankcase halves may leak. The gel seal is usually only applied to one side of the crankcase, the front side, only because it is easier to apply it here without having to work around the crankshaft/rods. Like I said, prep is super important. The crankcase halves must be perfectly clean (no old sealer left over) and flat. Too much sealer applied will get into the crank bearings/oiling passages, too little sealer might create crankcase leaks. Using too much sealer can actually “shim” the halves apart slightly as well. There are so many sealers on the market, but this job is critical, so I wouldn’t use anything other than the type M or a quality anerobic sealer made for sealing two stroke crankcase halves.
Feel free to post pictures of your engine parts if you have more questions.
