As I'm researching for a new (or new to me) boat, i'm seeing lots of rebuilds on power heads and lower units. Not sure why so many are failing, but just want to be prepared if I decide to buy a used boat with no warranty. Please, NO OPINIONS on why they fail or don't, maintenance, or any of that stuff..just the actual cost to repair them. Motor will be between 200 hp and 250 hp. For you guys that have actually had one done (no guessing here please) OR you're a mechanic who does them...what's the ballpark cost?

3to5 Grand power head,500-3500 lower unit.

cost will vary 3500 to 10,000 on power head 1500 to 4000 lower unit. This is from having two power heads and two lower units done. Doing it yourself having a shop do the work new or rebuild. You can do everything right and still have the motor pop.

Accurate estimate from what I've seen. There are some insurance companies that will cover mechanical break-down of powerheads and/or lower units so shop around if you're not totally committed to your current provider.

Back in 2014 I paid 5,500.00 for a new power head and lower unit on a 2005 225 HPDI. now I think the price for just a new power Head is around 7 grand from the last I heard.

I had a blown powerhead 5 months ago and just last week bent a prop shaft so these are real numbers. Keep in mind the powerhead was replaced under warranty and the lower unit was replaced under insurance so these are numbers from that. The workorder for the powerhead was right around $7,500 for parts and install. The lower unit parts and labor was just under $5,000.

About 10 grand.

To me, it al depends on what motor you have and what lower unit you have. The newer the motor (typically) the more expensive the rebuild. Also more popular motors are cheaper that have been around for a while... like 2.5 merc parts are abundant... optimax parts are pretty common too. SHO is newer, more expensive parts and harder to come by. Lastly a huge factor is which mechanic you take it to. Big name places and dealers cost a lot. They�ll do good work but it�ll be fulllll price. A smaller joint will charge less. You can also in some cases opt to do an �economy build� where for example... I had a 225 optimax once. It had one ring hang from bad injector on that hole. The other 5 cylinders were totally fine. I opted to leave them be with only 300 hours on the motor and we just �one holed� it. I walked out for $1500 cash and that motor still running great.
To answer your question: a full rebuild will be 3,000-6,000 on most motors. Any more than that and I�m going somewhere else. Unless it�s something new like a SHO... don�t think those Powerheads are cheap. Lower units are even more diverse..... costs all over the place. 1000-5000. Just depends on what motor.

I had a 225hpdi rebuilt with a whole new block by Hydrotech up in Nixa Missouri (december 12th), it cost right at 7grand to have that done. If your block is not damaged they said about $500 less

96 merc 225 rebuild power head and trim rebuild was $4,987 a month ago.

Question ?
Did you disassemble the motor from the boat and deliver it to Hydro ?

Nope i drove it up there, they worked on it on the boat. Replaced all my fuel lines and filters while it was there as well as ran it in a tank for an hr to make sure it was working correctly... It actually cost closer to $6300 now that i looked at the invoice, i think my quote to have it done down here was 7grand so i opted to drive it up there and save $700. Matt Worthy and his guys did a great job, they walked me through what they did and even went through and checked everything else with me there to make sure it was correct. I can not suggest these guys enough, they did a fantastic job and it was done same day. (dropped off at open and was out of there at 3pm)

OK,,,,,no you guys have got me scared.
I have had real good luck with used motors ...... Yamaha OX66 150
But I am looking at an 06 Merc 225 Pro XS
??????
Lower units are not an issue with stump / lake insurance.
Can you get insurance on a used motor/power head ?

That i am not sure about, but what i can tell you is my blown HPDI was my fault. The fuel line was corroded and starving the engine of fuel, make sure you check everything you can think of yearly. Things can still happen, but that can really mitigate the risks if you truly take good care of the motor

you can pay for lower unit insurance. I hit a rock and needed a new one. The bill was $4300 with a new prop. I paid a $500 deductible.