Misery Factor on Rebuilding Powerhead for 95 Mercury 200hp XRI

[saleenivey]

I wanted to see if anyone can tell me how much of a pain would it be to remove and rebuild this powerhead. I've got a reasonable amount of mechanical knowledge with automobiles. I would just hate to pay the kind of money these shops charge to rebuild a powerhead. Any advice would be appreciated!

[The Big Al]

It easy to work on the engine mechanically simple.

Some special tools, flywheel removal tool.

Lift ring to lift power head.

It's not a hard thing to do.

Lot of us here to walk ya threw it.

Once ya do it you find just how simple they truly are.
And at the same time how exact everything has to be.

Good machine work and quality parts are key to a good engine rebuild.


Al

[saleenivey]

This motor is used on a fishing boat so I'm not really in need of high performance parts. Who would you recommend I get the replacement pistons and rings through?? Also, if I were to buy a reman powerhead, any recommendations??

[Fish]

like Al said, not too tough. The one thing I would add to Al's list is a Mercury factory service manual. If you have a little mechanical knowledge, it will walk you through and you can always ask anything you can't find in the manual (or search function above) right here on the boards. Although I am not one of them, some of the best motor minds in the country are on scream and fly. good luck,

fish

[SatisfAction]

Rebuilding can be challenging but all-the-while fun at the same time. A manual, a few special tools, patience and a little bit of elbow grease is all it takes and the satisfaction of doing it yourself only adds to the fun after you're all done. Just make sure you have a neat and tidy workplace for disassembly and reassembly so you don't lose parts. I like to catalog everything in either ziplocs or shoeboxes. Whatever is easier and fits your fancy. Just don't get in a rush and you'll be fine.

[saleenivey]

If I go the route and purchase a reman powerhead, who is reasonbly priced and does great work??

[johnt]

get ready for some sticker shock even if you look at remanufactured powerhead!! this stuff ain't cheap..get a Mercury manual and go to work. I had a Seloc manual for the first one I did. It was okay but money will be well spent on a genuine Merc manual. Do not take your block for machining to an automotive shop, take it to someone knowledgeable with outboard motors. Get your parts from the vendors on this site and you will be pleased.

[Hottrucks]

Like everyone has said BUY A GOOD MANUAL.....

keep stuff clean , use lots of assembly oil and have at it.....

when you get past the out side stuff...electronics ( heres a hint once the fly wheel is off remove all electronics as a unit..stator to switch box plate don't remove all the wires one at a time)
I use a 2 liter Pepsi bottle rack (the ones they stack them in the stores in) it has 6 holes for bottles and allows you to put each piston assembly in one hole keeping your part separated and grouped together... with each head on the appropriate side....

and when you say rebuild do you mean fresh'n or is it broken??
Pro Marine is very good to deal with as far as parts and they are a vender here on the board.....

[diskvalve]

If you are mechanically inclined the rebuild is really quite straightforward. 1.Get the right mercury service manual (.off Ebay or from Mercury). 2. Mark your rod caps with a Sharpie indelible pen indicating which way is up and make sure you keep them matched to their respective rod and mark the rod as well to match which way it comes out. 3. Get a clean white sheet and neatly arrange all your clean parts on it before assembling. 4. When you install the rods on the pistons put the 24C grease in the freezer to stiffen it up and coat all the little rollers with it and (important do this part when you are well rested and unhurried ; first thing in the day preferred) .5.Get a rebuild gasket set . 6 Follow the manual for assembly and torque specs. Vertex pistons are good if you don,t want to use oem . These tips will help you if you decide to tackle it yourself.

[E-tec1]

why did it fail, figure that out so it dont happen again

[The Big Al]

I have manual if needed.

A MERCURY FACTORY MANUAL!!!!! NOT AFTERMARKET!!!

Al

my e-mail
smithkart@aol.com