87-91 200 E-Rude parts swap

Capt. Ron

Cadet
Joined
Mar 15, 2005
Messages
10
Can the flywheel from one work on the other?<br />Also can I move all or part of the electical system from one to the other?<br />I'll give you a little background here.<br />I took the 1991 engine and boat to a mechanic to get a carb rebuild he did the rebuild then called me to tell me that my powerpack was out. The boat ran fine as long as I choked it so I couldn't figure out how the power pack could be out but like a dummy I told him to go ahead and replace it. A week later this guy calls me to tell me that the magnets had "fallen" off of the flywheel and in turn had messed up my stator!!????? Funny the magnets seemed to be in place before I took it to them and there are no marks of any kind on the stator from loose magnets bouncing around under the flywheel.<br />Well it seemed obvious to me that FINISH LINE MARINE in Galveston,TX was trying to bleed me dry so the next day I drove from Dallas to Galveston to get the boat and refused to pay for anything but the carb work since that was what I took it to them for in the first place. They supposedly put the old powerpack back on my motor but one of the rubber connectors doesn't fit the wire on the motor quite right.???? Makes me wonder where this other powerpack came from. I've tried the motor and am getting no spark at all to the spark plugs. Now I have the 87 motor which I had just put new power packs on right before the power head went south on me due to VRO failure.<br />How can I test my current power pack and stator and if either are bad can I swap them out independantly or together as a unit?
 

seahorse5

Rear Admiral
Joined
Jan 24, 2002
Messages
4,698
Re: 87-91 200 E-Rude parts swap

The '86 and '87 engines used the same flywheel and igntion system that had twin power packs. For 1988 until '92 they changed the whole electrical system and added more internal electronics, QUICK-START and S.L.O.W systems. That meant a change in flywheels, a single pack, new timer base, shift switch, etc.<br /><br />In '93 there were more changes, but mostly in connections and wiring areas.
 

Capt. Ron

Cadet
Joined
Mar 15, 2005
Messages
10
Re: 87-91 200 E-Rude parts swap

So what your saying is I can't just swap the 87 flywheel over to the 91?<br />I've heard of epoxy kits to re-glue the magnets on the flywheel, is that advisable or should I not try that?<br />Also would moving everything from the 87 to the 91 work and would that be a good idea or should I stick with the current setup and just fugure out what is bad and what is not?
 

seahorse5

Rear Admiral
Joined
Jan 24, 2002
Messages
4,698
Re: 87-91 200 E-Rude parts swap

You can purchase the special epoxy and/or the individual magnets (comes with epoxy) from a dealer. <br /><br />Bead blast the inner part of the flywheel to remove all traces of rust. If any remains, it will "grow" and pop off the magnets again.<br /><br />I don't know if your older motor has all the same mounting holes, etc. to fit the newer parts. You would have to change the port cylinderhead so the new temp sender and temp switch assembly would fit. Your motor is a different block also. In '88, they increased displacement to 3.0L
 

Dhadley

Supreme Mariner
Joined
Feb 4, 2001
Messages
16,978
Re: 87-91 200 E-Rude parts swap

Yes the entire ignition from the 87 will bolt directly on the 92 but you will lose Quick Start, SLOW and the better rev limiter. Do not swap flywheels between the 2 systems. <br /><br />The heads from the older 2.7 will fit but you'll have to run hi test fuel because of the increased compresion.
 

Capt. Ron

Cadet
Joined
Mar 15, 2005
Messages
10
Re: 87-91 200 E-Rude parts swap

Thanks for the info guys.<br />Does the epoxy kit have any kind of guide or template to ensure proper placement of the magnets?<br />I wouldn't want to spend the time and money repairing my flywheel only to do it wrong.<br />Also I have this 87 motor that I had thought about trying to fix but at this point it may be more profitable to part it out. Can you suggest a particular sight or just do the ebay thing?<br />Looking at the powerhead the visible physical damage is a melted piston, broken rod and a hole in the plate that bolts up between the 2 cylinder banks. It seems that that plate should be replacable but I've been told that each of those plates are specifically mated to the power head. Anyone have any insight on that subject?<br />Thanks again
 
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