Honda 135 Sitting for Six Years

[BenMechamAZ]

I am in the process of rebuilding an old Yukon Delta 30-footer literally from the hull up for someone. It had been converted from an I/O to a Honda 135hp (I think fuel-injected) outboard about six years ago. It was tested in the local lake once, the guy subsequently ran out of money, and the project halted. It has been sitting in storage until now. The motor has less than an hour on it! After talking to mechanics about putting the motor back into service, I get all kinds of versions of "that's going to be a nasty job" and rough estimates of $1000 - $3000 of work! Needless to say, I don't have a very happy boat owner (who also happens to be a good friend of mine.)
My question is this: Is this something that I can handle on my own? I am not a mechanic by trade, but I have rebuilt engines, restored old cars, and do my own basic mechanic work when it's worth my time. However, all my experience is in AUTO mechanics, not MARINE. I feel a sort of mysticism surrounds marine mechanics, and if I look too hard at something on an outboard it will rust and fail.
Also, what parts might need to be looked at or replaced? I have some telling me it will probably just be the fuel system, others saying definitely the water pump, possibly a million other things as well...
Can I just pick up a service manual and have at it? Or is this something best left to the pros?
Please Help!

Thanks in advance,
Ben

 

[Sea Rider]

Re: Honda 135 Sitting for Six Years

Welcome to the forums,

Just by being marine you could get all sorts of price out of this world quotes for the engine comeback. If the engine has less than an hour not worry so much. Start getting a service manual so to know what you're doing. Is it a 2 or 4 strokes engine to start with. Could begin by removing all plugs and turn engine flywheel CW by hand to check if seized, if not, probably all the rest is just pure sitting time maintenance. Clean carbs, check impeller & gas pump diaphragm conditions change oil, change tail oil, clean tank and fuel line, filters, and that's it assuming has no electrical issues. Test with fresh fuel.

Could take pics while in the process of disassembling parts so to know how they looked before. If you remove carb pilot/screws measure screw's head/base hight with rear vernier protuding tip and place back on with same height.

Happy Boating

 

[multimech]

Re: Honda 135 Sitting for Six Years

It's a Honda, so it's a four stroke. Do a leakdown on the cylinders. If that is ok (less than 10%) the cylinders are alright to run. You may have to put some oil in the cylinders, because they are probably dry. After putting oil in the cylinders, crank the engine over without starting it, laynard out and get the oil flowing. If it is fuel injected. Turn on the key, do you hear a whirring sound? The pump is most likely alright. Now pull off the VST and check it for sludge. Pull the injectors and have them flow tested and cleaned. Check all of your fuel lines for breakdown, dry rot and etc. Check for good spark on all cylinders. Once you have done all of that, then put in fresh fuel. Change the oil. Start the engine. Don't forget the change the lower unit oil and replace the water pump. Probably should replace the thermostats as well.

 

[BenMechamAZ]

Re: Honda 135 Sitting for Six Years

Thanks for the replies,
Looks like I have a lot of work to do!
I'll let you know what I find out... this should be interesting.