Just how difficult is it to rebuild an outboard?

daselbee · Feb 16, 2011

Re: Just how difficult is it to rebuild an outboard?

CaneCutter79 said:
Nice tip!

Guess I need to look up what "fog it" means. I think I can find that through searching. Thanks again to all!

Excuse me for throwing water on your fire, but if you don't know what "fog it" means, maybe you are not ready for this rebuild. Sorry...just concerned that you may be in over your head before you start.

BoatingCop · Feb 16, 2011

Re: Just how difficult is it to rebuild an outboard?

Don't let anyone get you down. With a service manual and these forums you'll be just fine. The only way to learn is to do it and you learn by asking questions. We all started somewhere.

daselbee, just because he doesn't know the meaning of a term doesn't mean we should discourage him.

Carry on CaneCutter!

daselbee · Feb 16, 2011

Re: Just how difficult is it to rebuild an outboard?

BoatingCop said:
Don't let anyone get you down. With a service manual and these forums you'll be just fine. The only way to learn is to do it and you learn by asking questions. We all started somewhere.

daselbee, just because he doesn't know the meaning of a term doesn't mean we should discourage him.

Carry on CaneCutter!

I figured I would get a response or two or three like this...

It is not just the one term....most of his posts show a very green newbie.
I am just trying to warn him. If this is a sentimental motor to him...he needs help with this effort...or the motor is history.

Oh well...like the cop says...carry on. But just remember what I said also.

I do think that ol' jonesg was giving you a slight hint also...right at about post #28...the last line.

I will step out and leave you to it.

dehydrated · Feb 17, 2011

Re: Just how difficult is it to rebuild an outboard?

canecutter,read read,read, do your homework, there was never a stupid question that got answered! go slow through this project plastic bagies marked with specific bolts pay close attention to where each bolt comes out some are shorter for a reason draw up diagrams and take pics as you go clean everything and keep everything clean run into problems post it someone will help good luck

glengold · Feb 17, 2011

Re: Just how difficult is it to rebuild an outboard?

daselbee said:
Excuse me for throwing water on your fire, but if you don't know what "fog it" means, maybe you are not ready for this rebuild. Sorry...just concerned that you may be in over your head before you start.

I've been boating my whole life and never knew about fogging a motor till I got on this site..... of course, we don't winterize anything here in Florida so thats part of it

BoatingCop · Feb 17, 2011

Re: Just how difficult is it to rebuild an outboard?

glengold said:
I've been boating my whole life and never knew about fogging a motor till I got on this site..... of course, we don't winterize anything here in Florida so thats part of it

Thats the exact reason I love Texas! Well, unitl you have a freak winter storm! It got down to 15! Thats cold to us!!

jonesg · Feb 17, 2011

Re: Just how difficult is it to rebuild an outboard?

CaneCutter79 said:
HOLY COW! I got my Service Manual in the mail and it is EXACTLY what I needed. Most all of my questions can be answered within this book.
(this is probably where you experienced guys are thinking :facepalm

Give it a thorough reading, dismantle the engine in your mind, learn the steps.
Write the pertinent information inside the rear cover of the manual, compression numbers etc.
LEarn your engine , ask questions , then make a plan.

CaneCutter79 · Feb 26, 2011

Re: Just how difficult is it to rebuild an outboard?

jonesg said:
Give it a thorough reading, dismantle the engine in your mind, learn the steps.
Write the pertinent information inside the rear cover of the manual, compression numbers etc.
LEarn your engine , ask questions , then make a plan.

That's exactly what I'm doing. I'm not jumping in and breaking down everything. I prefer to research it, read the book, order special tools I don't have and need for the job, etc.

As for not knowing what fogging is, I Googled it and found a ton of information on it. Yes, I'm green but I learned from this forum of something I was not doing and needed to. It was a no-brainer once I found out what it was. I may not have known, BUT I know enough about mechanics to know what it does if you don't do it.

I prefer to learn and do the project myself. The main reason is the wife won't let me invest $2-3K for a rebuild of a 32yr old motor. She thinks I'm crazy! If I can do it for under $1k and learn all about the motor and have fun doing it, even better! I know that I paid attention to every detail and didn't rush the job. If I ever have to do it again, it will be easier the 2nd time. This boat has turned me on to older retro boats. It's a part of marine history and these old boats helped make the boating industry what it is today. I'd love to know all about my motor and the bragging rights of doing it myself. I can't wait to tell my former boat mechanic (a good friend) that I did it myself. I think he'd be impressed. I just can't afford him! (haha)

daselbee · Feb 27, 2011

Re: Just how difficult is it to rebuild an outboard?

Okee dokey...I will be glad to help with advice if I can. Just wanted to give you a bit of warning.

I will suggest one thing....start with the water pump. Do that job. Reading your book, and then performing that repair will give you an idea of the problems you can encounter. Then tackle the powerhead if you "feel the need".

Good luck.

CaneCutter79 · Feb 27, 2011

Re: Just how difficult is it to rebuild an outboard?

daselbee said:
Okee dokey...I will be glad to help with advice if I can. Just wanted to give you a bit of warning.

I will suggest one thing....start with the water pump. Do that job. Reading your book, and then performing that repair will give you an idea of the problems you can encounter. Then tackle the powerhead if you "feel the need".

Good luck.

Thanks for the help and I agree with your suggestion. I was already planning on doing just that. In case I panic and feel like I'm way over my head, removing the lower unit to get to the water pump is way less expensive and way less involved than taking apart the powerhead.

I know I can take the powerhead apart. It's getting it back together within the proper spec that I'm worried about. All the little things that a certified/trained mechanic would know from years of experience. That's what I don't have or access too. I could ask my mechanic for tips and I'm sure he would offer some advice but I feel bad doing that. That's like him asking me for free advise about my profession.

Here's a question.....

I know I have some minor binding in the motor. By binding, I mean there is noticable hesitation on one cylinder when the motor turns over. The motor runs fine. Heck, the motor runs great even. I just know that I have a low cylinder. I don't suspect the lower unit is the source. The service manual suggests to remove the lower unit, then test for binding. If no binding, then lower unit is the problem, if not, disassemble powerhead and inspect. I'm suspecting its the bad cylinder with low compression. When I test for compression and have all the plugs removed and guage connected to the low cylinder, the motor does not have any binding. When you test the other cylinders, there is a little binding.

So I assume I will be able to find the binding problem by looking at the powerhead and parts once it's disassembled? If I had a bad piston ring, that could be the problem but I would think low compression would make it easier to push the piston vs. harder to push the piston in the powerhead....

emdsapmgr · Feb 28, 2011

Re: Just how difficult is it to rebuild an outboard?

You may well find a difference when you remove the lower unit and spin the flywheel by hand. If you remove the lower and still have binding, you'll just have to tear into the powerhead for the answer. One thing to check for: When these engines get to the point where there is low compression on one cylinder, they may have a cracked piston ring. A common failure mode on older crossflow engines. A ring will break, then the edges of it can catch on the intake/exhaust ports each time the engine rotates. You can identify this failure by the pits in the head and piston top when the bits of ring get lodged in the head/piston top at top dead center. You could pull the heads off and inspect things prior to disassembly.

CaneCutter79 · Dec 15, 2012

Re: Just how difficult is it to rebuild an outboard?

Just an update to a thread from long ago...

I took the motor to a mechanic who specializes in older motors like mine. I didn't feel comfortable doing the work myself nor did I have time. In my experience, I usually spend double when trying to save money.

SO the results were....
- piston #4 had a hole in it and rubbed a gouge into the cylinder so it's getting re-sleeved
- piston #3 had a small hole in it but no re-sleeve
- piston rings were badly worn on all 4 pistons
- over-reving in driveway did not cause any binding problems, just blew out one of the piston rings and loss of compression which may have resulted in hole in piston
- crankcase looks great
- crankshaft is in great condition
- piston rods look straight and should be in good shape
- carb was in bad shape which may have been the cause of my blowby and other damage over time
- reeds and intake look great
- no boring, all cylinders will be factory spec when complete
- using fancy new Weisco tefflon coated pistons in all 4 cylinders
- full re-hone in 3 remaining cylinders only, no boring needed
- all new gaskets
- new carb rebuild
- possible new coils
- testing entire electrical system for any possible flaws where anything will need to be replaced
- new starter (not rebuilt) for only $100
- motor will be like new and have a 15month warranty

All of this for around $2,500 including parts/labor. I'm happy with that and after checking several shops, this was one of the cheaper bids and I know the mechanic cares about doing good work vs. the money. He's been sending me photos, keeping me updated, and answered every single multiple question I have asked. Very happy!

After reading many posts on here and help from others, I feel much more informed on the subject and I can tell if I'm being given a dose of BS. This guy is highly recommended and does great work. I'm happy! THanks again for everyone's help!