2.5 EFI Merc Question

[Richard]

I purchased a 1995 EFI 200 Merc several months ago from a reputable rebuilder. I followed his instructions for breakin to the letter. Last Sunday, I poked a hole in the rod end of the lower cylander on the right side. Since the motor is supposedly under warranty, I've been directed to remove the power head and either ship it or return it myself. I don't have a clue why this happend. the motor was never run very hard and never over 5400. That aside, I would like to remove the midsection for repainting and replace the stock cowl with a Bridgeport Cowl that I recently refurbished. What should I be aware of when performing these mods?

[Richard]

What I really need some advise with is once the powerhead is pulled, what is the procedure for pulling the midsection. It was once a Mariner that is now painted black. I want to strip it and repaint. Also in replacing the stock cowl with the Bridgeport cowl, how should the water discharge houses be routed? thanks for any help you can give.

[Gerben]

Hi Richard,

I'm no where near of an expert. Just a question, is the 5400rpm the max rpm it would run? Seems a bit low.

Gerben

[Richard]

This motor actually can run well up to 6,000 with the oil injection. This particular motor has had problems from the start. I think it was an issue of quality control in the rebuilding. I've had some issues that I straightened out myself. This motor never had the snap that it should. I wouldn't be surprised to find other problems once the powehead is removed and torn down. I won't comment at this point on the way is was rebuild until I have all the facts. Suffice it to say, I wasn't impressed with the quality of this motor. I learned some very good lessons through this process, most of them painful.

[Tony Brucato]

Richard,

Find out what caused that problem before you install a new long block.
That failure can probably be traced to fuel delivery or ignition troubles. Make sure it's corrected first, if you're planning to keep all of your accessory items.

Tony

[Richard]

The outfit that rebuilt it has offered a waranty. Since I'm not an accomplished Merc mechanic, I am somewhat at their mercy. I will, however post the name of the rebuilder if this problem is not corrected to my satisfaction. As I said, I was not completely satisfied with the way the motor was rebuilt. Had I known about this web site, I would have been much better off buying something from one of the subscribers. I've learned a very valuable lesson and I'm probably about to learn another one.

[Tony Brucato]

Richard,
In all fairness, give the rebuilder a chance to make it right. These things happen even with brand new motors from the factory.

Tony

[Richard]

tony:
Thanks for you thoughts. I'm just really frustrated at this point. Here are some of the reasons why: wires leading from the solenoid to the coils were nicked in several spots. Some were covered with tape, others were arching off the powerhead. Several of the bleed hoses were cracked and leaking fuel. The banjo on the oil injection pump was loose and leaking. The midsection was from a Mariner and the black paint that was sparyed over the top of the silver started peeling the minute it hit the water. That's part of the reason why I want to pull the midsection, strip it and repaint it.

[Rusrog]

Just a suggestion on the mid section....powder-coat it. It is a much more durable finish. I have a guy here in Fort Worth that does all of my stuff. He did mine for about $50 and he even sand blasted the old finish off and then coated it. It looks great and is super durable and easy to clean.

Just a thought,

Russ Rogers
Ft Worth TX

[Steven]

Richard, i have a midsection that has just been powdercoated. it has 4 exhaust relief holes straight out the back above the waterline. its pretty loud run that way without the liner, but you can plug these holes with drain plugs for the boat if it needs to be quiter. hasent been in water since it was pcoated. just a thought. im looking to get $100 for it. thanks and good luck with your powerhead. theres a pic of the mid on misc parts. thanks,steven