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Author Topic:   OptiMax 135 Rebuild

Whaler4good posted 09-18-2007 09:59 PM ET (US)
Two days ago I purchased a 2001 Dauntless 18 with a 2001 Mercury OptiMax 135. During tests it rode well, it seemed. After a grueling drive back home from Florida to Louisiana, I launched it the next day, didn't get more than a couple hundred yards, and it stopped. Diagnostics said it had only 159 hour since registration August, 2002 and cylinder #1 had 95-PSI, while the others had 125, 130, 130, 138, and 138-PSI. It needs a rebuild.
Is [rebuilding this Mercury OptiMax 135-HP motor] worth [the costs involved]? Or should I go to a new motor? The boat is in remarkably excellent condition, and I hate to part with it, but I can't use it presently.
jimh posted 09-18-2007 10:21 PM ET (US)
[This article was originally appended to a discussion on a different topic. I have moved it to the REPAIRS/MODS discussion so that it can receive proper attention on its own.]
jimh posted 09-18-2007 10:34 PM ET (US)
The decision to repair an engine versus replacing it is a difficult one to make, and more so in this case because the real history of the engine is not known, either by us, the readers, or by the owner.
There is a strong case for rebuilding the engine due to its very limited amount of use. An engine with less than 200 hours of use has hardly been used, and there ought to be plenty of life remaining in it, once repaired.
To correct problems with poor compression the usual method is a complete and expensive tear down of the engine, and replacement of the damaged areas. Because in this case the cylinder with low compression is not completely damaged, I wonder if it could be helped with some treatments for removing carbon build up. Perhaps a treatment with a solvent could "de-carbon" the cylinder and get some improvement. It would be worth a try. Consult with your engine diagnostician.
If a complete tear down is needed, my advice is to very carefully select the mechanic who will perform the work. When an engine is torn down and rebuilt there is a great expense in the labor, and most of the owner's investment in the rebuild will be an investment in the skill of the mechanic. If the mechanic does a first-class job the engine will be as good as new, and it will deliver many hours of good service. If the mechanic is not skilled, the engine may not run long enough to pay back the investment in its rebuilding.
Before any rebuilding is undertaken, it is absolutely necessary to identify what caused the problem to occur in the engine. If you do not remedy the problem which caused the cylinder failure, you will just damage the newly rebuilt engine when you begin using the engine again.
sosmerc posted 09-18-2007 10:46 PM ET (US)
I recommend you pull the cylinder heads so you can examine the condition of the O-rings that seal the cylinders (and take a carefull look at the cylinder walls for signs of severe scoring). You may get lucky in that maybe your engine needs repair, but not necessarily a complete major overhaul. I would also consider having both your fuel injectors as well as your direct injectors sent out to Brucato for cleaning and flow testing. A mechanic with a DDT diagnostic tool can evaluate any error codes that have been stored. If you repair the engine and put it back into service, be sure and have a technician reset the break-in procedure and clear all fault codes and run history.
Good luck...these are very nice running motors when all is well...and very fuel efficient.
A2J15Sport posted 09-18-2007 11:55 PM ET (US)
The bottom ends of those engines are pretty much bulletproof.
I'd be looking at top end (head gaskets, seals, etc.) long efore I took the engine apart.
If your repair facility wants to "rebuild it", at the drop of a hat, I'd get a second opinion.
Whaler4good posted 09-19-2007 10:22 PM ET (US)
I have a friend who has a 2000 135 optimax with 10 hours is it worth 35oo dollars? or am i getting into another problem. I figure maybe if it checks out by a mechanic with good compression I would have one with spare parts.
aussiejake posted 09-20-2007 01:02 AM ET (US)
I had 5 cylinders with around 30psi compression and one with 95psi on my 135hp 1999 optimax
Ended up being a stuffed head gasket. Replaced gasket and now have around 130psi on all cylinders with 700hrs on the motor.
As sosmerc said they are a very economical reliable motor, so I would be checking the easy stuff first, head removal takes 5 minutes.
good luck
Jake
aussiejake posted 09-20-2007 01:03 AM ET (US)
I had 5 cylinders with around 30psi
should have read 130psi :)
Whaler4good posted 09-20-2007 09:57 PM ET (US)
I hgad another mechanic look at it and he seems to think it can be fixed cheaper but recommended a new powerhead . He said he would fix the one in question but could,t guarrantee anything else would not happen. He also did a free diagnostic for me and told me things the dealer did't disclose and also saw where someone had cleared all previous codes or their problems. This engine showed overheating on the starboard side where all other cylinders were okay. I also was offered another 2004 Yamaha 150 carbuerator type installed new with 1 year factory warranty for 5500 dollars. I am leaning toward this because I don't have that much for a new powerhead plus labor. The new powerhead was about 5800 dollars. Does this sound crazy I am really having a hard time deciding
Whaler4good posted 09-20-2007 10:05 PM ET (US)
Does the Yamaha 150 with carbs get very decent gas consumption? It's an '03 or 04'
an86carrera posted 09-20-2007 11:12 PM ET (US)
$3500 is not too bad. You could part out your old one and reclaim $1500-2000.

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Author	Topic: OptiMax 135 Rebuild
Whaler4good	posted 09-18-2007 09:59 PM ET (US) Two days ago I purchased a 2001 Dauntless 18 with a 2001 Mercury OptiMax 135. During tests it rode well, it seemed. After a grueling drive back home from Florida to Louisiana, I launched it the next day, didn't get more than a couple hundred yards, and it stopped. Diagnostics said it had only 159 hour since registration August, 2002 and cylinder #1 had 95-PSI, while the others had 125, 130, 130, 138, and 138-PSI. It needs a rebuild. Is [rebuilding this Mercury OptiMax 135-HP motor] worth [the costs involved]? Or should I go to a new motor? The boat is in remarkably excellent condition, and I hate to part with it, but I can't use it presently.
jimh	posted 09-18-2007 10:21 PM ET (US) [This article was originally appended to a discussion on a different topic. I have moved it to the REPAIRS/MODS discussion so that it can receive proper attention on its own.]
jimh	posted 09-18-2007 10:34 PM ET (US) The decision to repair an engine versus replacing it is a difficult one to make, and more so in this case because the real history of the engine is not known, either by us, the readers, or by the owner. There is a strong case for rebuilding the engine due to its very limited amount of use. An engine with less than 200 hours of use has hardly been used, and there ought to be plenty of life remaining in it, once repaired. To correct problems with poor compression the usual method is a complete and expensive tear down of the engine, and replacement of the damaged areas. Because in this case the cylinder with low compression is not completely damaged, I wonder if it could be helped with some treatments for removing carbon build up. Perhaps a treatment with a solvent could "de-carbon" the cylinder and get some improvement. It would be worth a try. Consult with your engine diagnostician. If a complete tear down is needed, my advice is to very carefully select the mechanic who will perform the work. When an engine is torn down and rebuilt there is a great expense in the labor, and most of the owner's investment in the rebuild will be an investment in the skill of the mechanic. If the mechanic does a first-class job the engine will be as good as new, and it will deliver many hours of good service. If the mechanic is not skilled, the engine may not run long enough to pay back the investment in its rebuilding. Before any rebuilding is undertaken, it is absolutely necessary to identify what caused the problem to occur in the engine. If you do not remedy the problem which caused the cylinder failure, you will just damage the newly rebuilt engine when you begin using the engine again.
sosmerc	posted 09-18-2007 10:46 PM ET (US) I recommend you pull the cylinder heads so you can examine the condition of the O-rings that seal the cylinders (and take a carefull look at the cylinder walls for signs of severe scoring). You may get lucky in that maybe your engine needs repair, but not necessarily a complete major overhaul. I would also consider having both your fuel injectors as well as your direct injectors sent out to Brucato for cleaning and flow testing. A mechanic with a DDT diagnostic tool can evaluate any error codes that have been stored. If you repair the engine and put it back into service, be sure and have a technician reset the break-in procedure and clear all fault codes and run history. Good luck...these are very nice running motors when all is well...and very fuel efficient.
A2J15Sport	posted 09-18-2007 11:55 PM ET (US) The bottom ends of those engines are pretty much bulletproof. I'd be looking at top end (head gaskets, seals, etc.) long efore I took the engine apart. If your repair facility wants to "rebuild it", at the drop of a hat, I'd get a second opinion.
Whaler4good	posted 09-19-2007 10:22 PM ET (US) I have a friend who has a 2000 135 optimax with 10 hours is it worth 35oo dollars? or am i getting into another problem. I figure maybe if it checks out by a mechanic with good compression I would have one with spare parts.
aussiejake	posted 09-20-2007 01:02 AM ET (US) I had 5 cylinders with around 30psi compression and one with 95psi on my 135hp 1999 optimax Ended up being a stuffed head gasket. Replaced gasket and now have around 130psi on all cylinders with 700hrs on the motor. As sosmerc said they are a very economical reliable motor, so I would be checking the easy stuff first, head removal takes 5 minutes. good luck Jake
aussiejake	posted 09-20-2007 01:03 AM ET (US) I had 5 cylinders with around 30psi should have read 130psi :)
Whaler4good	posted 09-20-2007 09:57 PM ET (US) I hgad another mechanic look at it and he seems to think it can be fixed cheaper but recommended a new powerhead . He said he would fix the one in question but could,t guarrantee anything else would not happen. He also did a free diagnostic for me and told me things the dealer did't disclose and also saw where someone had cleared all previous codes or their problems. This engine showed overheating on the starboard side where all other cylinders were okay. I also was offered another 2004 Yamaha 150 carbuerator type installed new with 1 year factory warranty for 5500 dollars. I am leaning toward this because I don't have that much for a new powerhead plus labor. The new powerhead was about 5800 dollars. Does this sound crazy I am really having a hard time deciding
Whaler4good	posted 09-20-2007 10:05 PM ET (US) Does the Yamaha 150 with carbs get very decent gas consumption? It's an '03 or 04'
an86carrera	posted 09-20-2007 11:12 PM ET (US) $3500 is not too bad. You could part out your old one and reclaim $1500-2000.