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It's off-season and I'm thinking about my engine. My '92 Johnson 90 has been around the block. I have no idea how many hours are on it, but I'm sure it's a bunch. The VRO needs to be replaced, there was water in the lower unit oil--not a lot, but it at least needs to be re-sealed--some hoses are looking worn, a couple of clamps have broken, and so on. Compression? No idea exactly, though the guy I bought the boat from said it had been recently tested and was about 105 across the board, and in any case it still gets my 16SL up to 40 mph. Oh, and it's recently developed a ticking at certain rpm ranges, whether a bearing in the lower unit or the engine or something else, who knows. A couple of times a year I go out on the ocean around Boston, and I'd hate to get stranded.

So, thoughts turn to a new engine. Quieter, better fuel economy, more reliable.

On the other hand, I only use the boat about 50 hours a year, so fuel use isn't a big deal, and I don't really find the engine that loud. Thinking about it reliability is my main goal. I suspect a rebuild will get me what I want, but I've never gone that route before, nor do I have any idea what a reasonable cost is or how to judge value, though I would guess a quality job is expensive, it would be much cheaper than new. Thoughts appreciated.

John K.

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I would price a new motor and get a quote on a complete overhaul on the one you have. See which one reflects best with your budget.

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I went thru the same thing. It was a little over double the cost of rebuild to buy a new motor. But the new motor came with new controls, better fuel consumption, runs quieter and has a warranty.

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I would answer a few questions first before deciding to rebuild or buy a new motor.

Is the boats condition worthy of a new motor? Do you plan on keeping the boat for many years or is an upgrade in the near future on your list?

The mechanic that will do the work on the old motor is probably the best guy to ask. I would certainly want to be very confident in his abilities and expertise as well as with his prices.

A brand new motor with good warranty sure will bring some peace of mind and go a long way with the reliability factor. I would also want new steering and controls and new gauges if I was buying a new motor.

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Different things to think about, what kinda shape is the engine in? salt or fresh water use? Rust? Any other major repairs? I have a 1985 140 Looper will run it until it dies, only problem is these OMC 4 cylinders from the mid 80's to early 90's are bullet proof (one of the best outboards made) Your water in the lower unit can only come from three places bad seal on the oil plug, bad seal on the prop gasket (happen to mine) bad seal on the inside by the water pump, thats it unless it cracked. Without seeing the condition of the engine I can not make a fair decision. However Gamalot has some good statements, I would not purchase a new engine and then sell the boat in two years. but you can purchase a lot of gas with the price of a new engine....Clear as mud

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Although the boat is a 1991, the hull is in fantastic shape. Very little water intrusion, some interior spider cracks, but nothing on the outside. I plan on keeping the boat a long time since it's just the right size for my family and the kind of use I give it. Next step looks like a discussion with a repair shop. I don't think I can justify a new boat unless this motor's really shot.

John K.

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The other thing to consider is that even though the power head will be rebuilt, key parts like the coils, power packs, stators, lower unit, etc, will still be 20 years old with hundreds of hours time on them (unless you're planning on swapping them too). Not a huge deal if one of those goes out, unless you're miles off shore, but it's a short season up here as you know, and losing time on the water due to a pita factor was enough for us to go new and not rebuild. It's proven to be a great decision for 4 trouble free seasons.

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It was worth upgrading to a modern engine for my 91 Outrage simply to get rid of the carbs. My old Merc had some issues but still ran strong. However significant corrosion of many of the top-end fasteners, degradation of the wiring insulation, and other significant signs of age had started to worry me. Two full seasons now with the a new Etec and I couldn't be happier. It starts easily every time, is so much more quiet, much better fuel efficiency, and I haven't missed a single minute on the water due to a mechanical issue.

A new engine and rigging wasn't an inexpensive option but I plan on having my little Outrage for as long as I am physically able to launch and retrieve her.

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if you are still looking or considering a rebuild. Myself and a good friend of mine do rebuilds and outboard engine work on the side from school and are looking for some more work. Matt is my partners name, and he has rebuilt three V-4's now, all came out perfect, and all ran fantastic. We would need specifics to give you an accurate price, but as a reference point he just did a 1994 150hp Mariner for $2400.

If you have any interest, again, just shoot me an email and we can discuss.

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John K.
We went thru the same turmoil of what to do back in 2007 regarding our original Yamaha 90 2 stroke which was failing on us. In the end the decision became apparent....a new Honda 90 4 stroke. Haven't regretted it for one minute since. While the cost of each is much different, cost alone was not the single deciding factor. A few of the key aspects of our decision were: We planned on keeping A Little Madness until we can't boat anymore; we wanted the quiet & fuel efficiency; we go out in the Atlantic as well and reliability was paramount (also the basis for choosing a Honda); and we added the Sea Star Hydraulic Steering for ease of steering. As you can see on our personal page, we've done a lot of renovations to her, with the final to come being the interior surface next year. So I guess we're trying to say, put all your thoughts together, pause, and the answer will be there for you. Good Luck!