Morgan Out Island 41

Built 1971–? by Morgan Yachts

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About the Morgan Out Island 41

Researched from public sources for this model. Any individual boat may have been modified or repowered — confirm before relying on any figure.

Built: 1971–?
Builder: Morgan Yachts
Designer: Charles Morgan
Length: 41.25 ft
Waterline: 34 ft
Beam: 13.82 ft
Draft: 4.17 ft
Ballast: 9,000 lb
Hull / keel: full keel
Rig: sloop
Propulsion: inboard
Fuel: 138 gal
Water: 170 gal
Water heater: 6 gal · AC + engine · standard
Generator: factory option
Stern thruster: not fitted
Steering: hydraulic

Tank capacities — where the figures come from

Fuel 138 gal
“Fuel Tankage (Aluminum Tank) 138 gallons; Fuel tankage - 138 gal. in single welded aluminum baffled tank” — owner's manual, dv-fansler.com · “The fuel tank holds 138 U.S. gallons” — search excerpt, en.wikipedia.org · “Fuel: 140 gallons” — search excerpt (1979), dv-fansler.com

Morgan Yacht's Out Island 41 owner's manual (62 hp Perkins era) gives 138 gal in one aluminum tank, matching our earlier figure.
Water 170 gal
“Water Tankage (2 Aluminum Tanks) 170 gallons” — owner's manual, dv-fansler.com · “fresh water tank has a capacity of 170 U.S. gallons” — search excerpt, en.wikipedia.org · “Water: 170” — search excerpt (1979), dv-fansler.com · “215 gallons of wa[ter]” — search excerpt (1976), boattrader.com

The owner's manual gives 170 gal in two welded aluminum tanks, matching our earlier figure. A 1976 listing says 215, and SpinSheet magazine notes original water and waste tanks were often replaced, so individual boats vary.
Holding unknown
The owner's manual describes heads plumbed to holding tanks (plural) with deck pump-out, but gives no capacity.
Water heater 6 gal · AC + engine · standard (Raritan)
“Hot water heater - 6 gal. Raritan w/engine by-pass & 115 vac element” — owner's manual (OI 41 (415) standard package, hull 110 o), dv-fansler.com

From the Out Island 41 (415) standard package list in the Morgan owner's manual, marked effective from hull 110; earlier hulls aren't confirmed.

Tanks are often replaced or added on older boats — check the tank labels or a survey for yours.

Thrusters and steering — where this comes from

Bow thruster unknown
The builder's owner manual (standard equipment list and systems) mentions no thruster.
Stern thruster not fitted
The builder's manual lists no thruster and no option list was found, so our earlier figure of none is kept but not proven.
Steering hydraulic
“Pedestal mounted Hynautic hydraulic steering unit w/stainless steel destroyer wheel” — owner's manual, dv-fansler.com · “The steering system in your OI-41 is relatively maintenance free ... The reservoir, relief valve, and actuating cylinder” — owner's manual, dv-fansler.com

Morgan's Out Island 41 owner manual shows a Hynautic hydraulic helm in the centre-cockpit pedestal with a destroyer wheel, a pressurised reservoir and cylinder under the aft bunk, an emergency tiller and provision for a second station. The manual is for Perkins 4-154 boats (late 1970s on); earlier boats weren't checked.

Thrusters and steering are often replaced — check the units on your boat before ordering parts.

Sources disagree on displacement, number built, when the Westerbeke 4-107 was fitted — left blank rather than guessed.

Center-cockpit three-cabin cruiser with many interior layouts over its run; a walk-through to the aft cabin was added in 1974, and a large share of boats went into charter. Sloop or ketch; a few had centerboards. Early boats used the Perkins 4-108 or Westerbeke 4-107, later ones the Perkins 4-154 (sailboatdata lists 62 hp). Displacement is disputed (24,000 lb at launch vs 27,000 lb in 1981 literature). Sail area grew from 683 to 775 sq ft with a taller rig. After Catalina bought Morgan, the 41 Classic (fin keel, skeg rudder, Yanmar diesel) replaced it; last year of the original not found. Structurally regarded as sound; windward and light-air downwind performance is poor.

Engines fitted

Perkins 4-108 — diesel, single standard
Early boats (sailboatdata; Wikipedia names it as the fitted engine). Wikipedia attaches '62 hp' to the 4-108, but sailboatdata's 62 hp figure goes with the later 4-154, so hp is left blank.

Sources: sailboatdata.com · en.wikipedia.org
Perkins 4-154 — 62 hp, diesel, single standard
Morgan switched to the 4-154 later in production (also standard on the OI 416 derivative).

Sources: sailboatdata.com · en.wikipedia.org
Westerbeke 4-107 — diesel, single factory option
Alternative to the Perkins; sailboatdata places it on early boats, Wikipedia on later boats.

Sources: sailboatdata.com · en.wikipedia.org

Boats of the same model can differ — check which engines yours actually has before ordering parts.

Generator

factory option

“A.C. Generator Option - The A.C. generator option presently being installed is an Onan 7.5 KW diesel powered unit.” — owner's manual, dv-fansler.com

Builder owner's manual lists the AC generator as an option.

Onan — 7.5 kW, diesel factory option
The manual calls this the unit being installed at the time, so earlier boats may differ. The generator mounts on a platform in the engine room above the reserve water tank.

“Onan 7.5 KW diesel powered unit” — owner's manual, dv-fansler.com

Generators are often replaced or added — check the unit's own plate before ordering parts.

Known problems for this model

Low hull-to-deck joint on early boats hull
Boats built before 1975 have the hull-deck joint well down the topsides, where docks and travel-lift slings can damage it; from 1975 the joint moved to the deck edge.
spinsheet.com
Failing polyethylene water and waste tanks plumbing
The original plastic tanks are prone to failure and were installed before the deck went on, so same-size replacements are nearly impossible without major work; owners usually fit several smaller tanks instead.
spinsheet.com

Engines & parts

Perkins 4.108 parts: good

Factory standard engine — you entered “Perkins 4-108”

Out of production but very well supported. Trans Atlantic Diesels (TAD) sells complete aftermarket rebuild kits (pistons, liners, rings, bearings, gaskets, valves, guides, seals), heads, blocks, crankshafts, genuine Perkins camshafts, rebuilt injection pumps and injectors, Jabsco/Sherwood raw water pumps, heat exchangers, starters, alternators and elbows, plus rebuilt exchange engines. The Westerbeke 4-107/4-108 family and some industrial engines share the base design.

Parts sources: Trans Atlantic Diesels (TAD), Foley Engines

Common problems (1)

Rear main (crankshaft) seal leak engine
The original rope-type rear seal is notorious for leaking and often starts leaking again a few hundred hours after replacement; Foley sells a nylon/Teflon replacement seal meant to cure it, and owners check the crankshaft sealing surface for pitting.
foleyengines.com · boatdesign.net · forums.sailinganarchy.com

Maker’s service schedule (13)

Engine oil & filter change 4.108(M) marine	150 hrs or 3 mo	“4.107(M) and 4.108(M) Engines ... Every 150 hours or 3 months (whichever occurs first). Drain and renew lubricating oil” — manufacturer (1973), fujiyachts.net
Fuel filters & water separator 4.108(M) marine	400 hrs or 1 yr	“Every 400 hours or 12 months (whichever occurs first). Renew final fuel filter element.” — manufacturer (1973), fujiyachts.net
Air filter / intake silencer 4.108(M) marine	150 hrs or 3 mo	“Every 150 hours or 3 months (whichever occurs first). ... Clean air intake gauze.” — manufacturer (1973), fujiyachts.net
Drive belts inspect / replace 4.108(M) marine	150 hrs or 3 mo	“Every 150 hours or 3 months (whichever occurs first). ... * Check drive belt tension.” — manufacturer (1973), fujiyachts.net
Valve clearance check / adjust 4.108(M) marine	2,400 hrs	“Every 2,400 hours ... Check and adjust valve tip clearances.” — manufacturer (1973), fujiyachts.net
Injector test / service 4.108(M) marine	2,400 hrs	“Every 2,400 hours ... Service atomisers.” — manufacturer (1973), fujiyachts.net
Transmission fluid change 4.108(M) marine	400 hrs or 1 yr	“Every 400 hours or 12 months (whichever occurs first). ... Change gearbox oil.” — manufacturer (1973), fujiyachts.net
Clean water trap 4.108(M) marine	150 hrs or 3 mo	“Every 150 hours or 3 months (whichever occurs first). ... Clean water trap.” — manufacturer (1973), fujiyachts.net
Check engine for oil and water leaks 4.108(M) marine	150 hrs or 3 mo	“Every 150 hours or 3 months (whichever occurs first). ... Check engine for leakage of oil and water.” — manufacturer (1973), fujiyachts.net
Lubricate dynamo rear bush (where fitted) 4.108(M) marine	150 hrs or 3 mo	“Every 150 hours or 3 months (whichever occurs first). ... Lubricate dynamo rear bush (where fitted).” — manufacturer (1973), fujiyachts.net
Check hoses and clips 4.108(M) marine	400 hrs or 1 yr	“Every 400 hours or 12 months (whichever occurs first). ... Check hoses and clips.” — manufacturer (1973), fujiyachts.net
Drain and clean fuel tank 4.108(M) marine	400 hrs or 1 yr	“Every 400 hours or 12 months (whichever occurs first). ... Drain and clean fuel tank” — manufacturer (1973), fujiyachts.net
Examine and service starter motor, generator etc. 4.108(M) marine	2,400 hrs	“Every 2,400 hours Arrange for examination and service of proprietary equipment, i.e. starter motor, generator, etc.” — manufacturer (1973), fujiyachts.net

Service part numbers (7)

Oil filter later engines with spin-on filter	Perkins 2654403	“A genuine Perkins 4.108 oil filter - OE Part No. 2654403 ... Fits 4.108 and 4.108M.” — dealer, parts4engines.com · “Filter, Oil late type long 2654403, Length 130mm - 2654403” — dealer, lancingmarine.com
Oil filter early engines with element-in-canister filter	Perkins 26540154	“A genuine Perkins 4.108 Oil Filter - OE Part No. 26540154” — dealer, parts4engines.com · “Filter, Oil early type 26540154, Length 122mm - 26540154” — dealer, lancingmarine.com
Fuel filter cartridge-type filter housing (most engines)	Perkins 4326658 Replaces 26561117 Also: Delphi (CAV) 296	“A genuine Perkins 4.108 fuel filter - OE Part No. 4326658 ... supersedes ... 26561117.” — dealer, parts4engines.com · “Fuel Filter (296) Was 26561117 Now 4326658” — dealer, lancingmarine.com
Fuel filter early engines with bowl-type filter housing	Perkins 30242	“A genuine Perkins 4.108 fuel filter element - OE Part Number 30242 ... fitted to early Perkins 4.108” — dealer, parts4engines.com · “Filter element, Fuel old type 30242, Length 74mm small element - 30242” — dealer, lancingmarine.com
Raw-water impeller Jabsco raw-water pump (3270, 3370-200 or 9970-200)	Jabsco 1210-0001	“4.107M / 4.108M / LL 9970-200 040 3/4" BSP Flange SK229 3298 1210-0001” — manufacturer, marineengine.com
Raw-water pump kit Jabsco 9970-200 pump	Jabsco SK229	“4.107M / 4.108M / LL 9970-200 040 3/4" BSP Flange SK229 3298 1210-0001” — manufacturer, marineengine.com
Raw-water pump kit Jabsco 3370-200 pump (obsolete)	Jabsco SK33	“4.107M / 4.108M / LL 3370-200 ... 9970-200 SK33 3298 1210-0001” — manufacturer, marineengine.com

From the engine maker’s parts lists, or two independent parts dealers. Numbers change with serial number and get superseded — check yours before ordering.

Perkins 4.154 parts: limited

Factory standard engine — you entered “Perkins 4-154”

Less common than the 4.108/4.236 and marine-specific parts are thinner. Owners report the original Jabsco/Sherwood raw water pumps have been discontinued; TAD, Depco and Parts4Engines are the usual sources, and TAD sells rebuilt drop-in 4.154 engines.

Parts sources: Trans Atlantic Diesels (TAD), Parts4Engines (Perkins 4.154 & 200 series)

Common problems (2)

Discontinued raw water pump cooling
The factory raw water pump models are no longer made, so owners hunt for used pumps, rebuild parts or an adapted substitute through specialists.
trawlerforum.com
Rebuild vs. repower decision engine
Owners of tired 4.154s frequently debate rebuilding the old engine versus repowering because of parts cost and scarcity.
cruisersforum.com

Maker’s service schedule (12)

Engine oil & filter change 4.154M marine	150 hrs or 3 mo	“Every 150 hours or 3 months (whichever occurs first) Drain and renew engine lubricating oil (see page 27). Renew lubrica” — manufacturer (1974), fujiyachts.net
Fuel filters & water separator 4.154M marine	450 hrs or 1 yr	“Every 450 hours or 12 months (whichever occurs first) Renew final fuel filter element.” — manufacturer (1974), fujiyachts.net
Clean sedimenter water trap 4.154M marine	150 hrs or 3 mo	“Every 150 hours or 3 months (whichever occurs first) ... Clean sedimenter water trap.” — manufacturer (1974), fujiyachts.net
Air filter / intake silencer 4.154M marine	150 hrs or 3 mo	“Every 150 hours or 3 months (whichever occurs first) ... Clean air intake gauze or screen.” — manufacturer (1974), fujiyachts.net
Drive belts inspect / replace 4.154M marine	150 hrs or 3 mo	“Every 150 hours or 3 months (whichever occurs first) ... Check drive belt tensions.” — manufacturer (1974), fujiyachts.net
Injector test / service 4.154M marine	450 hrs or 1 yr	“Every 450 hours or 12 months (whichever occurs first) ... Service atomisers.” — manufacturer (1974), fujiyachts.net
Transmission fluid change 4.154M marine	450 hrs or 1 yr	“Every 450 hours or 12 months (whichever occurs first) ... Renew gearbox lubricating oil.” — manufacturer (1974), fujiyachts.net
Valve clearance check / adjust 4.154M marine	2,400 hrs	“Every 2,400 hours ... Check and adjust valve tip clearances.” — manufacturer (1974), fujiyachts.net
Check engine for oil and water leaks 4.154M marine	150 hrs or 3 mo	“Every 150 hours or 3 months (whichever occurs first) ... Check engine for leakage of oil and water.” — manufacturer (1974), fujiyachts.net
Check hoses and clips 4.154M marine	450 hrs or 1 yr	“Every 450 hours or 12 months (whichever occurs first) ... Check hoses and clips.” — manufacturer (1974), fujiyachts.net
Drain and clean fuel tank 4.154M marine	450 hrs or 1 yr	“Every 450 hours or 12 months (whichever occurs first) ... Drain and clean fuel tank.” — manufacturer (1974), fujiyachts.net
Examine and service starter, generator etc. 4.154M marine	2,400 hrs	“Every 2,400 hours Arrange for examination and service of proprietary equipment, i.e. starter, generator, etc.” — manufacturer (1974), fujiyachts.net

Model sources (4)

sailboatdata.com · spinsheet.com · en.wikipedia.org · dv-fansler.com

Other Morgan models

Morgan 382 / 383 / 384 1977–1986
Morgan Out Island 33 1973–?

Researched from public sources. Spotted an error? The sources are listed above — tell us what they got wrong.