Four-Stroke Powerhead Break-In
1st Hour: Operate the engine at varying speeds up to 2000 RPM or approximately 1/2 throttle.
2nd Hour: Increase the engine speed until the boat is on a plane, avoiding full throttle operation. Vary engine speed up to 3/4 throttle.
Next 8 Hours: Run the engine at any safe speed. However, avoid operating at full throttle for more than five (5) minutes at a time.
After the first 10 hours of use, change the oil and oil filter. Inspect for any oil or water leaks.
After this service, operate the engine normally. With each use after break-in, it is recommended to operate the engine at full throttle, at least once for a brief period, as can be done safely. This helps with the carbon buildup and cylinder glazing.
Oil System Cleaning (Short blocks, cylinder heads, long blocks)
It is critical to thoroughly clean the midsection and oil pan to avoid contaminating the new powerhead or cylinder head. On VVT engines, this includes inspection and cleaning of pulleys and solenoids. Also, removal and replacement of the oil pickup screen is recommended.
Complete disassembly and cleaning of the oil pan is recommended. It is also recommended to change the oil and oil filter after the first 30 minutes of running on a test tank.
Failures due to contamination of oil system are not covered under warranty.
Short Blocks
In addition to the oil system cleaning, the following should be performed:
- Inspect and clean cylinder heads. Confirm no debris is present, valve shimming is in spec, water passages are clean, and head surfaces are within tolerance.
- Inspect and replace as necessary: timing belts, tensioners, and pulleys.
- It is recommended to replace the oil pump and balancer (where applicable).
- Confirm timing has been set per manufacturer's procedures.
- Always use premium oil as recommended by the OEM manufacturer.
Note:
*All OBR Remanufactured Yamaha F200/F225/F250 3.3L short blocks require 6P2-13300-00-00 (YA-282) Oil Pump
*All OBR Remanufactured Yamaha 2.7L F150 short blocks require 63P-13300-02-00 (YA-281) Oil Pump
Cylinder Heads In addition to the oil system cleaning, the following should be performed:
- Confirm shortblock head surfaces are clean and within tolerance.
- Inspect and clean shortblock water passages.
- Inspect and replace as necessary: timing belts, tensioners, and pulleys.
- Confirm that there is no contamination remaining from prior failure (see oil system cleaning).
- Replace head bolts as necessary.
- Depending on prior failure, replacement of oil pump may be required.
- Set timing per manufacturer procedures. Improperly setting the timing may cause irreparable damage that is not covered under warranty.
Two-Stroke Powerhead Break-In
This powerhead is replacing one that has failed prematurely. Powerhead failure is usually due to excessive combustion chamber temperature. You must find the cause of this failure, or the same problem will occur again. Our experience is that the piston is the part that fails first, usually caused by detonation. The following tips may help you avoid repeat failure:
Carbureted and EFI 2-Stroke Powerheads
- Have all injectors cleaned and flow tested. Replace injectors that are out of specification.
- Rebuild carburetors and/or fuel pump.
- Replace water pump and gaskets at time of powerhead replacement and every year. Use newest style gaskets.
- Check overheat and oil alarm horn for proper function.
- Replace all fuel filters. Confirm fuel quality with a fuel sample.
- Verify fuel pressure on EFI engines is to specification.
- Replace or check all switch boxes and ignition modules.
- We recommend installing a water pressure gauge to monitor water flow in the engine.
- Use mid-grade octane major manufacturer fuel without alcohol.
- We recommend removing the oil injection system
- OMC: If retaining oil injection system, update to the latest VRO pump.
- Mercury: If oil injection is used, replace 2-PSI oil valve and check oil pump bushing and seal.
- Clean and refill oil tank with TCW-3 oil.
- Verify oil consumption by marking oil tank during double oil break-in period if running oil injection.
- Double your oil with a major manufacturer TCW-3 oil for approximately 30 gallons of fuel. If running oil injection, add 1 pint of oil to 6 gallons of gas. If no oil injection, add 1 quart of oil to 6 gallons of gas. Does NOT apply to direct-injected motors.
- At completion of break-in, inspect powerhead for any leaks. Check and re-torque fasteners as necessary.
- Confirm any service bulletins have been addressed.
DFI (Optimax, HPDI, FICHT, ETEC)
- Double oiling should be set by the ECM/ECU.
- Fuel injectors/air injectors must be flowed and tested. Replace internal filters.
- Replacing the injector from the failed cylinder is recommended due to contamination.
- Fuel system must be cleaned to remove any prior contamination -- includes fuel rail, VST, fuel lines, etc.
- Fuel pressure is critical in these applications. Confirm high and low pressures meet specifications. This may require computer software to monitor these readings.
- Replace all fuel filters; confirm fuel quality with a fuel sample.
- Replace water pump and gaskets at time of powerhead replacement and every year. Use newest style gaskets.
- We recommend installing a water pressure gauge to monitor water flow in the engine.
- Use mid-grade octane major manufacturer fuel without alcohol.
- Verify oil consumption by marking oil tank during double oil break-in period.
- At completion of break-in, inspect powerhead for any leaks. Check and re-torque fasteners as necessary.
- Check overheat and oil alarm horn for proper function.
- Confirm any service bulletins have been addressed.
The first 10 HOURS of your new engine's life are very important. Please use the following information as a guideline.
- Do not perform break-in on water hose.
- Double your oil with a major manufacturer TCW-3 oil. (Excludes direct-injected engines.)
- DFI engines should be set to break-in mode through the ECU.
- Use a mid-grade octane major manufacturer fuel without alcohol.
- Engines should be slowly brought up to normal operating temperature to avoid cold seizure.
- For the first hour, operate the engine at a varied speed of 700-2,500 RPM to break in new pistons and rings.
- During the next 6 hours, operate the engine in gear at no more than 4,500 RPM. Accelerate using only enough throttle to bring the boat up on plane quickly.
- Vary your engine speed by accelerating to 3/4 throttle for 1 to 2 minutes. Continue to vary throttle through break-in.
- During the final 3 hours, you may operate the boat at wide-open throttle for periods of less than 2 minutes.
- At completion of break-in, verify oil system is working as designed.
- Inspect powerhead for leaks. Check and re-torque fasteners as necessary.
Lower Unit & Sterndrive Break-In
- Gearcase assemblies are shipped without oil.
- Fill unit with manufacturer's required gear oil to recommended level.
- Adjust RPM at idle to manufacturer's specifications.
- Proper shift adjustment is essential.
- JUMPING OUT OF GEAR: If the unit will not stay in gear, the clutch dog has probably been rounded off. Rounded clutch dogs are caused by, but not limited to, improper shift cable adjustment, inadequate shift travel, idle RPM too high, and/or shifting too slow. Rounded clutch dogs are NOT covered by warranty.
- Avoid full throttle starts.
- DO NOT operate at constant speed for extended periods.
- Shift into forward gear a minimum of 10 times during break-in, with moderate engine speed after each shift.
- DO NOT exceed 75% of full throttle during the first hour of operation.
- During the next 5 hours, full throttle should not be maintained for long periods.
OMC and Mercruiser Sterndrive Service Notice When purchasing either an upper or lower assembly separately, the opposite piece must be disassembled and cleaned by the service center in order to validate the warranty. This provision is due to the cross contamination of the oil.