Yamaha Rebuild Options

Tunacious D

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Looking for some advice on options. One of our 93 200's had rings come apart on one cylinder most likely due to a leaking head gasket. There is some damage to the cylinder wall which will require a sleeve to be installed. The piston will have to be replaced since there is a nick or groove on one edge and some dings in the top from the ring pieces contacting the top of the piston and the bottom of the head. The head is nicked up some as well. I think that is the only damage to an otherwise solid motor but not sure since we haven't broken it down yet. I am not in a position right now for new engines nor have I been able to find recent model used HPDIs that I would consider to be cost beneficial.

Been looking at turnkey rebuilders (they get the engine, do the teardown, machining, and installation of new parts. Some offer warranties of 6 months to 5 years. I wouldn't hang my hat on the warranty since most have language in their warranty that would (at least in my opinion) make a claim nearly difficult to prove so I am not hung up on that.

My second option would be to get a rebuilt (short) block including new rings, pistons, bearings, etc. and reassemble ourselves and send our block back as a core charge (most likely get screwed here too).

Last option would be to take it to a Yamaha or reputable mechanic and let them do their business. At least they would be able (hopefully to evaluate the whole engine and make sure the failure wasn't caused by something other than the assumption of a leaking head gasket).

My concern is that I have heard that rebuilds (may) have a short lifespan which is causing my concern. Is there any truth to this? Any of you running rebuilt blocks that have high hours? There are a couple of rebuilders saying that they torque the heads before they machine and do a special resurfacing that replicates the factory finish. Anything to that?

The costs all appear similar and are around $3,000 to $4,000. Thanks all for your suggestions, opinions, etc. in advance.
 

BobP

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When you get the engine straightened out, whatever way you go, and intend to stay with the present twins for some time, you may want to consider shopping a private seller for a used engine of similar vintage to keep as a spare. Many guys upgrading to 4 strokes with perfectly good low hour old 2 strokes, $2K will do it. RH or LH rotation doesn't matter, just take you time and get the best condition, sea trial (desirable), and compression test. Place an ad saying you are looking for an engine, guys on the fence for 4 stroke repowers may get them motivated.

Then the next time if something does go wrong, lower unit, T&T, powerhead, your down time is limited to one day, no rush to decide on options for the faulty one, and at a cost savings many times. The spare engine can even be used as an instant source for major spare parts avoiding the OEM crazy prices. You don't need a costly bracket to store the engine, I did it with concrete blocks, scrap wood, and one piece of angle iron from the Depot for $15.

I'm with you on those warranty offers. I bet the 5 yr warranty costs what they charge for the work, so it's twice the price or more.

Good luck.
 

Grog

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I can't recall anyone posting how good their rebuilt engine is but there are many bad ones. Look into a Yami short block but there are other parts that might need attention pretty soon like the lower unit. When removing the engine block a few bolts are sure to snap in the block which may add to the rebuild cost.