The rbuid has started
 

I have a '87 150 Suzuki 20" shaft that runs great but not a fan of the 20" transom. It only gives you about 4-5" of freeboard at the transom. Less than that when your standing back there fishing. The transom rebuild is next. I cant bring myself to spend $12-$15,000 on a new etec. So I searched craigslist and found a '99 225 suzuki with low hours with a bad piston for $600. The rebuild has started this motor is in great shape besides the bad hole. I will hopefully have another couple hundred dollars with a new sleeve and piston. I will let you know how it goes.

more pics
 

A few more...

now THAT's a HOLE!!!

I'd pull the other side just to inspect since it's apart.

Holy grail of holes. That joker was lean. Did you figure out why it went south? I am sure it all comes apart and goes to the machine shop Chiefsurfer.

Big hole
 

The other side looks like new, the engine has been rebuilt some time recently by a marine machine shop in Fort Lauderdale. When I was taking the motor apart I notice the injector for that cylinder was partially unplugged. I think the mechanic that assembled the motor didn't plug the injector electrical plug in all the way or it came lose which gave it an eratic injection.

Stupid question, Why does each cylinder have two spark plugs?

better man than I, I didn't even see that. I am assuming that it had an a-frame piston, which would greatly benefit from 2 ignition zones, rather than just the one.

http://www.freeflowmoto.com/ekmps/sh...001-1783-p.jpg

Although the pictures he has are a flat piston, so I am completely baffled now.

Redundant I think, like the NAP-Z Nissan 4-bangers they used in pick-up trucks. 2 plugs per hole.
You gotta know that engine was making some noise and running like crap before/during all that damage.
It is nice to find the "a-ha" when one goes south and takes out a piston.
Rebuilt a 1996 200 Merc that had tried to stick 2 pistons. New sleeves, pistons, rings machine shop inspected the block. Paid one of the best mechanics I have ever known to go through everything(carbs, 100% new electronics, link and sync broke-in and run on the dyno to verify motor was tuned properly and happy. Conservative set up as per Merc. Break-in was an easy 20 hours under 5000 rpm and the first time I leaned on it for no more than 30 seconds, It tried sticking the same pistons. Never figured it out. Couldn't risk another rebuild so I parted it out.

Piston
 

From '86 to around 2001 Suzuki made what they call a Super Six. I few different theories of why they did thisand what it means. The 150 Super Six which what is on my boat, they say is rated at closer to 200hp, back in the 80 the bass boat guys put a 150hp restriction on bass boat tournament class. So, Suzuki put two plugs per cylinder, slapped a 150 cowling on a 200 and spanked all the other boats out there. They also got in trouble from the NMMA. Other say it was to help in long periods of idling for trolling and such. Won't foul plugs... I tend to believe the first one. My boat runs pretty well. If nothing else it looks cool. It has regular dome type pistons as shown by the picture.

The 150 super six and 225's got the dual plugs due to the aggressive porting. Be careful rebuilding a 225 as it is a boron coated sleeve to handle the HP with small displacement design. Many will put steel sleeves in, but they do not hold up like the boron ones did. See if you can find a good block jug as that is a modular engine and you can replace the cylinders and pistons without pulling the powerhead. And have the injectors cleaned and flow tested by a reputeable shop as that is the #1 killer of EFI 2 strokes.