How to change cowling on older Merc 200?

[jesss55]

I am looking to replace the stock cowling on my 1984 Merc 200 with cowling from an 1993 Merc 200. Can anyone tell me what all is involved in this swap?

Thanks for the help-

Jess
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[fastskeeter]

just make sure you have ALL the pieces parts off of the newer cowling and bolt it back up to your motor. should be no problem

[outboards4life]

if it is a bucket style cowl you need 2 exhaust adaptor plate gaskets and you need to pull the powerhead off to do it. 1 gasket on the bottom of the cowl plate and 1 on top. drop the powerhead on and hook up the lines and cables and drop your cowl over it. takes some time but not a big deal.

[pyro]

...not with the cowling in question. It's not a hi-po cowl & pan setup, the one he's upgrading to has a clamshell lower cowl set that fits onto rubber-isolated mounting bars that bolt onto the mid adapter, fore and aft. The top bucket cowl just latches onto the lower set.

You may have to drill and tap bolt holes in the mid adapter for the forward mount.

[jesss55]

Thanks for the useful advice. Are there any concerns with drilling and tapping into the mid-section for the lower cowl mounts?

Jess
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[pyro]

The area where the forward bar mounts, is in front of the gasketed area of the mid adapter, nothing there to harm. The bolts are short.

[kingsbiship]

The rear bracket will attach to the three bolts holding the mid-plate down.
Cut the bracket holes so you only have to loosen the bolts and slide it in.
You won't be able to get the bolts out without lifting the P/head.

[Tregaskis]

If you are going to change cowlings on your 200, do you plan to sell the original? If you are and if they are decent, I am interested.

Thanks
Greg Yancey
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[jtb]

If you are going to change cowlings on your 200, do you plan to sell the original? If you are and if they are decent, I am interested.

Thanks
Greg Yancey
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if he is not selling i may i may have a set for you. please check with him first i don't want to hijack his thread.
PM me if you are interested

[jesss55]

My 1984 cowling is now available. I will be posting it in the misc parts forum in the next couple days.

I installed the newer 1993 "bucket" cowling earlier today. Below is a step by step procedure for the changeover.

1. Removed the "clamshell" cowling, cowling pivot brackets, and the cowling front latch assembly.
2. Changed the lower cowling seals to the new style seals to match the bucket cowling.
3. Installed the new lower cowling rear mount as instructed by slotting the holes for installation onto the mid unit bolts.
4. Set the lower cowls in place to position the front mount and marked its location.
5. Secured the front mount by drilling holes for the outer two mounting bolts.
6. Removed the factory air box to make room for the new cowling.
7. Installed the lower cowlings and bolted them together.
8. Installed a new "pee line."
9. Mounted new front cowling latch.
10. Installed bucket cowling.

Entire project took approximately two hours.

Thanks for all of the great advice.

Jess
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[jesss55]

My original 1984 Clamshell cowling is now listed for sale in Misc Parts forum. It is in excellent condition.

Jess
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