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Author Topic:   90 HP Engine Failure Help / Warranty

jmontani posted 11-29-2005 02:05 PM ET (US)
I am relatively new to larger outboard engines.
My 2005 Montauk was put into service in Mid-August. The engine is a 90hp - 2 stroke Saltwater with an estimated 25 hours on the engine.
I followed the break-in procedure and always top-off the oil when I get gas.
Last week the engine died completely while running on plane and could not be restarted. I took it to a Warranty Merc Shop and found out today that one of the cylinders failed and the powerhead needs to be replaced.
My questions are...
1. This seems like a major issue for such a new engine. (25 hours into life)
2. With this issue, I am not certain that I do not have a lemon engine and I am considering demanding a replacement vs. warranty work.
Is this over re-acting?
If one of the cylinders is bad, isn't it safe to say that the other two could have just as poor workmanship causing this same issue 3 months from now?
Just looking for a little guidance.

bsmotril posted 11-29-2005 02:21 PM ET (US)
It is not unheard of, especially if that motor set for a long time unused between outings. I doubt though that is the situation in your case since you just started using it in August. If your state has a lemon law for boats, you should familiarize yourself with the requirements for documentation and claim submissions. You can demand replacement under the lemon laws, but only after the Dealer has had several chances (law will tell you how many) to repair and make good the situation. In your case, their next step will likely be replacement of the powerhead. Usually, the factory wants the original back for analysis when there has been a low hour failure on a new motor. If the motor has been trouble free other than this failure, I see no reason to demand replacement of the entire motor versus just the powerhead. BillS
Plotman posted 11-29-2005 08:27 PM ET (US)
First - one problem does not make a lemon engine. Second, if you are getting a new powerhead, then you are getting a new engine - that's what the powerhead is, the engine part. I can't imagine why the lower unit, cowl, mid section, etc would need to be replaced.
In a normal powerhead replacement, they will also transfer the electrical componants and things like the carbs to the new engine block. What you don't want them to do is rebuild THAT powerhead for you.
jmontani posted 11-29-2005 09:40 PM ET (US)
Thanks for all the help.
The claim was approved and the new Powerhead is on the way. It is just irritating that I haven't had my new boat for 4 months and I am running into this type of problem.
The one good thing is that it's better to have this happen now under warranty than in month 13.

Clark Roberts posted 11-30-2005 08:01 AM ET (US)
Jmon, suggestion: check out the boat's entire fuel system from tank to engine! If engine failure was caused by a fuel delivery problem then it will happen again with new powerhead. Especially check for clogged on-board fuel filters, squeeze ball/// etc//etc.
The Judge posted 11-30-2005 12:06 PM ET (US)
Make sure they find out WHY it imploded. My bet is a lean carb adjustment from factory/dealer. It could also be a clogged port, bad injection line, etc etc.
jmontani posted 12-18-2005 07:55 PM ET (US)
Well the new powerhead is on. I am going to pick up the boat after the first of the year and run it with the mechanic on board to make sure that everything is OK.
The cause turned out to be an "assembly issue" according to Mercury. The mechanic found metallic debris in the original powerhead. It looked like busted/twisted metal pieces about the size of a dime. He did confirm that it was not an issue of oil or fuel delivery and that the filter was in good shape.
The retail cost for the repairs would have run about $4500. I will give Merc credit for the speed in processing, shipping, and authorizing the warranty work.
Hopefully I have had my big issue with this boat.
Thanks for all of your help.
Jack

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Author	Topic: 90 HP Engine Failure Help / Warranty
jmontani	posted 11-29-2005 02:05 PM ET (US) I am relatively new to larger outboard engines. My 2005 Montauk was put into service in Mid-August. The engine is a 90hp - 2 stroke Saltwater with an estimated 25 hours on the engine. I followed the break-in procedure and always top-off the oil when I get gas. Last week the engine died completely while running on plane and could not be restarted. I took it to a Warranty Merc Shop and found out today that one of the cylinders failed and the powerhead needs to be replaced. My questions are... 1. This seems like a major issue for such a new engine. (25 hours into life) 2. With this issue, I am not certain that I do not have a lemon engine and I am considering demanding a replacement vs. warranty work. Is this over re-acting? If one of the cylinders is bad, isn't it safe to say that the other two could have just as poor workmanship causing this same issue 3 months from now? Just looking for a little guidance.
bsmotril	posted 11-29-2005 02:21 PM ET (US) It is not unheard of, especially if that motor set for a long time unused between outings. I doubt though that is the situation in your case since you just started using it in August. If your state has a lemon law for boats, you should familiarize yourself with the requirements for documentation and claim submissions. You can demand replacement under the lemon laws, but only after the Dealer has had several chances (law will tell you how many) to repair and make good the situation. In your case, their next step will likely be replacement of the powerhead. Usually, the factory wants the original back for analysis when there has been a low hour failure on a new motor. If the motor has been trouble free other than this failure, I see no reason to demand replacement of the entire motor versus just the powerhead. BillS
Plotman	posted 11-29-2005 08:27 PM ET (US) First - one problem does not make a lemon engine. Second, if you are getting a new powerhead, then you are getting a new engine - that's what the powerhead is, the engine part. I can't imagine why the lower unit, cowl, mid section, etc would need to be replaced. In a normal powerhead replacement, they will also transfer the electrical componants and things like the carbs to the new engine block. What you don't want them to do is rebuild THAT powerhead for you.
jmontani	posted 11-29-2005 09:40 PM ET (US) Thanks for all the help. The claim was approved and the new Powerhead is on the way. It is just irritating that I haven't had my new boat for 4 months and I am running into this type of problem. The one good thing is that it's better to have this happen now under warranty than in month 13.
Clark Roberts	posted 11-30-2005 08:01 AM ET (US) Jmon, suggestion: check out the boat's entire fuel system from tank to engine! If engine failure was caused by a fuel delivery problem then it will happen again with new powerhead. Especially check for clogged on-board fuel filters, squeeze ball/// etc//etc.
The Judge	posted 11-30-2005 12:06 PM ET (US) Make sure they find out WHY it imploded. My bet is a lean carb adjustment from factory/dealer. It could also be a clogged port, bad injection line, etc etc.
jmontani	posted 12-18-2005 07:55 PM ET (US) Well the new powerhead is on. I am going to pick up the boat after the first of the year and run it with the mechanic on board to make sure that everything is OK. The cause turned out to be an "assembly issue" according to Mercury. The mechanic found metallic debris in the original powerhead. It looked like busted/twisted metal pieces about the size of a dime. He did confirm that it was not an issue of oil or fuel delivery and that the filter was in good shape. The retail cost for the repairs would have run about $4500. I will give Merc credit for the speed in processing, shipping, and authorizing the warranty work. Hopefully I have had my big issue with this boat. Thanks for all of your help. Jack