300 hr Service on the Whaler
Well, 300 hrs has popped up pretty quickly since I got the Boston Whaler 235 / Mercury Verado 250 hp last April with only 46 hrs on the clock. Racked up 250 hrs in 14 months with a 200 hr service I did in between, which is pretty simple, engine and leg oil.
The boat and motor have been nothing short of sensational. Cant rate the Whaler high enough, I love the boat and the motor. I was not a fan of the Verado prior to getting one, with concerns of them being too complicated, but in reality, they are quiet, very powerful, quite simple and I do all the maintenance myself.
Below is a bit of a pictorial and commentary of the 300 hr service, showing it is easy to do yourself BUT does come with a few potential issues........
1. Got quotes for a 300 hr service, which is the biggie with new spark plugs, all new filters (oil/fuel) and new water pump. Eye watering amount....stuff that, I will be doing this myself. Saved a packet BUT I did have a few issues.....
2. Got most of the parts local. Most parts are reasonably priced compared with on the net so I support local firms where possible. Only exception was spark plugs.....I refuse to pay $36/plug........$10.50 on the net for the exact same top end iridium plug, delivered in 4 days. Got a manual (CD) off ebay for $29, well worth it, full workshop manual. Very easy to follow down to pulling the entire engine to bits. Yanks make great manuals!
3. Changed engine and leg oil, did filters, a few new anodes, cleaned up all the other anodes, easy peasy.
4. Ripped the leg off......easy.
5. Snapped one of the water pump bolts off......easy..........phark!
6. Had a few beers over much swearing. It seems the factory does not apply any grease on the threads, and the recommendation is to pull out the water pump impeller at 100 hrs mainly just to get some grease on the bolts before they sieze up.....they are only M6 bolts, and stainless, so gutless.....
7. Drilled and easy out.....not so friggen easy. I hate easy outs and they don't normally work....this was no exception, ended up drilling the bolt right out, stuffing the thread.
8. Re-tapped next imperial size up (1/4).....looked dodgy but after a few beers looked OK.
9. Put it all together with a new impeller....after 300 hrs the old impeller appeared almost brand new. New impeller cheap insurance.
10. Back together. All good......
11. Could not sleep that night.............thoughts of being out at the shelf and the water pump crapping itself had me a bit nervous.......phark.
12. Buy a helicoil kit the next day.
13. Leg back off.
14. Drill, tap, helicoil.
15. Re-installed......only took 1.5 hrs to pull the leg off, install the helicoil, put the water pump back in and put it all back together.....easy second time round.
Well, it did take me a bit longer than expected, but I saved over $600 by doing it myself, have a few more tools I did not have before and know a lot more about my motor. Recon the 600 hr service will only take a few hours.
Good fun!
Boston Whaler 235 Conquest......getting the flogging it was built for.
Rob H
Posts: 5796
Date Joined: 18/01/12
cant see the pictorial?
cant see the pictorial?
Give a man a mask, and he'll show you his true face...
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Everyone's just winging it.
JohnF
Posts: 2836
Date Joined: 07/07/10
look again
look again
Boston Whaler 235 Conquest......getting the flogging it was built for.
dkonig82
Posts: 2091
Date Joined: 06/07/10
Good work John - I can
Good work John - I can imagine the swearing when the bolt snapped haha
When asked by a non-fisherman 'how many fishing rods do you really need?' the correct answer is either:
n+1 (where n is the number of fishing rods you currently own); or
n-1 (where n is the number of fishing rods which would cause your significant other to dump you.
Rob H
Posts: 5796
Date Joined: 18/01/12
had exactly the same on one
had exactly the same on one of my Suzy's except they are 8mm, fitted a helicoil.
Do you get your parts local or ex-US?
Give a man a mask, and he'll show you his true face...
The older you get the more you realize that no one has a f++king clue what they're doing.
Everyone's just winging it.
Rig
Posts: 2925
Date Joined: 27/12/06
merc
I wouldnt be too worried about snapping the bolt John, happened to one of my mates when he got his merc serviced and the dealer slugged him extra for fixing the bolt, sounds like you saved yourself more than $600 and it was done properly
Nauti Buoy
Posts: 595
Date Joined: 20/04/09
Great work
saved some serious cash, now you can spend 600 on some more fishing gear-hahah
Rob H
Posts: 5796
Date Joined: 18/01/12
what can work with the
what can work with the snapped bolt is, after drilling the centre but before trying the easyout spray it with the freeze spray so the cold can get right down inside it and shrink/expand.
Give a man a mask, and he'll show you his true face...
The older you get the more you realize that no one has a f++king clue what they're doing.
Everyone's just winging it.
AaronC
Posts: 118
Date Joined: 26/10/11
Great work,amazing how a few
Great work,
amazing how a few beers makes it look better.
dont know if i would be that confident doing all that work. Changing bearings is about my limit atm.
Did you by the boat with anti foul or have you put that on since you have had it?
DTrain
Posts: 486
Date Joined: 10/02/12
My mechanic said that even
My mechanic said that even though they recommend changing the impellor every 300 hours / 3 years it's better to change once a year just so you loosen all the bolts and can put some grease on them. I originally figured he was just trying to make extra money off me, but he may have a valid point.
81macca
Posts: 270
Date Joined: 02/07/09
When it does brake down off
When it does brake down off the shelf because all your experience came from Google, lucky sea rescue will be there to tow you home. Leave it to the experts I say.
I actually fish.
Rig
Posts: 2925
Date Joined: 27/12/06
experts
just like the NOR suzuki dealer experts
I hear what your saying 81macca but some people claiming to be the experts aint just that, experts are few and far between
Toby Roe
Posts: 118
Date Joined: 01/02/10
Probably can
Probably can have more confidence knowing he did it himself
Rob H
Posts: 5796
Date Joined: 18/01/12
John is an engineer I
John is an engineer I believe, from memory.
I do all my own as well and travel long distances in my boat.
At the end of the day Id rather breakdown cos I f++ked it up than because some other bloke on $175hr screwed it up.
If you have basic mechanical skills, other than the diagnostic program there is no mystery in a service and you will learn skills useful to you at sea.
Give a man a mask, and he'll show you his true face...
The older you get the more you realize that no one has a f++king clue what they're doing.
Everyone's just winging it.
Lamby
Posts: 3145
Date Joined: 04/08/09
Great thread, cheers John
Great thread, cheers John
Rob H
Posts: 5796
Date Joined: 18/01/12
Interesting from an
Interesting from an engineering standpoint that Merc specify 25w50 oil, you dont see that these days much.
Give a man a mask, and he'll show you his true face...
The older you get the more you realize that no one has a f++king clue what they're doing.
Everyone's just winging it.
unhurry
Posts: 236
Date Joined: 23/10/12
good for you mate
Well doen and thank yuo for sharing; clearly this is not rocket science and a little guidance and confidence can assist in achieving much.
Paul H
Posts: 2104
Date Joined: 18/01/07
well done, serviced a mates
well done,
serviced a mates reel earlier this year - over tightened a side plate bolt and snapped it, ordered another and snapped it again putting the new one in - You swear louder the second time around........
I wonder if the second one will fall out from being too loose :-)
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Paul G
Posts: 5215
Date Joined: 12/12/07
Great job and money well
Great job and money well saved. I do have an expert that as done my work for the last 3years and I am happy paying the extra, but hear what others are saying I would not let any yard touch my outboard .Had them f%$%$ one motor but hell try and prove it, no chance. .Plus im not that confident i would come back from my next trip out if I messed with the Honda. Good read thoe and good to see you having a crack .
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holth
Posts: 812
Date Joined: 09/10/06
Well done John. Ive been
Well done John. Ive been wanting to do my own for awhile. Just got to get a service manual of ebay. Ive watched my mobile guy do it 3 times and its all pretty straight forward. Just need confidence in your own ability. Unfortunately my motor being a old carbi 4 stroke l will leave the balancing of the carbies to him.
Rob H
Posts: 5796
Date Joined: 18/01/12
service manuals-google it cos
service manuals-google it cos you can them off various sites such as slideshare and others.
I got the electronic Suzuki factory manual for my DF115's for $8.95 instant dowload using paypal, also for my F115 Yam, Hilux and quadbike
Give a man a mask, and he'll show you his true face...
The older you get the more you realize that no one has a f++king clue what they're doing.
Everyone's just winging it.
new age
Posts: 330
Date Joined: 15/03/13
Do you use loctite on your
Do you use loctite on your helicoils?
Rob H
Posts: 5796
Date Joined: 18/01/12
not sure if you mean to
not sure if you mean to install the helicoil or for the bolt in the helicoil, but the helicoil itself bites into the new thread and doesnt need it.
The helicoil itself is actually a better setup than the orginal thread and is stronger than original thread into softer metals like ally.
Give a man a mask, and he'll show you his true face...
The older you get the more you realize that no one has a f++king clue what they're doing.
Everyone's just winging it.
new age
Posts: 330
Date Joined: 15/03/13
to install the helicoil i
to install the helicoil i read somewhere that it was meant to stop the helicoil from unscrewing or from twisting but like you say its suppose to bite in and might not be necessary
Rob H
Posts: 5796
Date Joined: 18/01/12
Ive never seen it used or
Ive never seen it used or needed to, the tool that installes the coil twists it from the bottom so as you wind it in, it compresses then springs out when released.
i havent ever seen one come out but if you loctite the bolt in it may try to.
Give a man a mask, and he'll show you his true face...
The older you get the more you realize that no one has a f++king clue what they're doing.
Everyone's just winging it.
JohnF
Posts: 2836
Date Joined: 07/07/10
Yeah, no Loctite on the
Yeah, no Loctite on the helicoil although I admit I considered it, they apparently expand a bit into the new thread which is designed to be a bit tight. A better option is a full thread like the Time-Serts or Keen-Serts, but the helicoil more than adequate I think for a low stress area like the water pump. The kits are only $35 from Covs, which is about as cheap as you can get off the web.
Macca, I understand your point but I have built a few motors for my race car, rebuild turbos etc so have a bit of mechanical idea, but to be honest, by doing it yourself you get to know your motor much better and if something does go wrong, at least you will have a chance of fixing it on the run.
I got all the parts local, most parts pretty reasonable compared with off the web and I rally would rather support local guys as long as I am not getting gouged.
The point of the thread is that a full 300 hr service is well within the capability of most people who have some mechanical knowledge, and the 100/200 hr service should be within the capability of anyone who can tie their shoelaces.
The savings are significant, the satisfaction of doing something yourself is a bonus.
Now to spend the savings on something shiny......
Cheers
Boston Whaler 235 Conquest......getting the flogging it was built for.
81macca
Posts: 270
Date Joined: 02/07/09
I just found it amusing that
I just found it amusing that the engine is only 300hrs old and bolts are braking? I fully agree that most dealerships are ripping us off blind for our outboard services. I do mine myself but I am a qualified mechanic and I can also keep my warranty and stamp my own book.
I actually fish.
Paul H
Posts: 2104
Date Joined: 18/01/07
I do deal with warranty
I do deal with warranty issues from time to time and my understanding is that servicing an outboard yourself should not be a problem with warranty at all (same goes for a car). Despite what many manufactures/dealerships and warranty's say you have statutory warranty law that supersedes the normal warranty as long as you could prove the following.
1. you did it (parts/oil receipts etc)
2. were competent enough (have some mechanical aptitude and - did it as per service manual your honour)!
The only problem you would have would be if they were able to prove the problem occurred as a direct result of something you did wrong (which would be quite difficult to prove) and/or you had another problem that needed to be looked at that was outside the bounds of normal servicing (so assuming your motor is behaving normally with no issues there shouldn't be a problem).
I'm no lawyer but have a fair understanding of statutory warranty law (but stand to be corrected).
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thesupervisor
Posts: 1136
Date Joined: 10/06/09
low grade stainless bolts
low grade stainless bolts into ali then soaked in saltwater for 300 hours
its not a fool proof formula bolts can and will break under them circumstances
getting the bottom line final answer from a bunch of blokes that use false names and put smiley faces at the end of paragraphs is not the best place in the world to get the information you seek.
JohnF
Posts: 2836
Date Joined: 07/07/10
MaccaYeah, I was pretty
Macca
Yeah, I was pretty bloody surprised the bolt snapped as well, but it was as I was trying to loosen it so it was not like I was ham fisted and over tensioned it.
As you would know, 316 bolts (particularly in M6 size) are not the most robust things ever made.....316 SS into ali with no grease on the threads from the factory is not going to pretty in a marine environment after 300 hrs it would seem. The moral of the story is to pull them out regularly and earlier than 300 hrs/3 years as the manual suggests. It is only a few hour job. A heads up for everyone.
As for warranty, the Merc owners manual clearly indicates the owner can do his own 100 and 200 hr services and keep the warranty. You don't need to be a mechanic. Not sure about the 300 hr, but mine is an import so no warranty anyhow.
I kind of agree that if you are not mechanically minded, then it may be best leaving the 300 hr service to a qualified mechanic.
My old man completely rebuilt 2 x 115 hp 2 stroke outboards a few years back, right down to new pistons, rings, big ends....very cheap to do himself and no harder than a car or motorbike engine, only difference is the workshop costs seem to be extreme with marine stuff if someone else does it for you......granted, the consequences of a breakdown with a boat are more life threatening, but if your careful and have a clue, why not back yourself?
Boston Whaler 235 Conquest......getting the flogging it was built for.
johno
Posts: 468
Date Joined: 20/07/08
Well done good read on the
Well done good read on the experience... totally can understand the sleepness night and I even learnt something new, never seen thread repair kits before Cheers
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Brock O
Posts: 3224
Date Joined: 11/01/08
Top stuff john
Never had any luck with stainless bolts, always bind, offshore we avoid them unless ss to ss even though it's common to see them in other materials.
I never considered playing with my last motor ( first boat ) as it was an 07 model and the fact the inlaw is an out board mechanic. Like you say, if your handy enough, have the manual, use quality parts then it's not out of reach. Next boat motor I'll tackle myself giving it will be an older model.
Macca, not trying to be smart but your first and second comments are miles apart. Being a mechanic I'm sure you've had issues with ss bolts.
spinksy
Posts: 266
Date Joined: 06/10/10
Great work John
And i agree totally these services are fairly easy for someone with some mechanical knowlege and why not if there is no warranty on the motor the savings are huge, You get to know your motor,And the work is done with some TLC. Even the best mechanics miss things as they are so busy these days and if they never had the parts to sort the bolt issue they probably would have gone with the original fix and rolled the dice.
Cruise Control
Posts: 973
Date Joined: 03/11/10
Great work John and agree
Great work John and agree this is the best way to provide some added protection should something go wrong in a remote area. Unfortunately, I'm too ham fisted to do this type of thing without some solid guidance but I take my hat off to those who can do it.
stilly
Posts: 341
Date Joined: 10/08/09
good to see someone having a crack
straight services are relatively easy for anyone with a little mechanical background to do on their own, it is always going to benefit yourself if things breakdown on you on the water, the money you save doing it yourself can be rewarding, have you given any thought to the things a marine mechanic may see though while doing the service that the average jo may not see?
JohnF
Posts: 2836
Date Joined: 07/07/10
Yep, I give it lots of
Yep, I give it lots of thought. That's why I do the services myself, I am a member of the Verado's owners club in the US with access to several Verado qualified mechanics on-line, have a full workshop manual etc.
The main worry I have is not with an experienced marine mechanic doing my motor at the workshop nor the cost, its the inexperienced apprentice that he leaves on the job.
Agree, if your the average Jo then the standard services are achievable but leave the major services to a good workshop or experienced mechanic.
Boston Whaler 235 Conquest......getting the flogging it was built for.