Advice/Tips needed to help us swap out merc 25hp 4strokes on pontoon

[Angie Northern WI]

We have 2 almost identical Northwoods pontoons and 2 almost identical merc motors.
Problem is, we want to frankenstein them out so that our nicer pontoon has the nicer(newer) motor.

Same size same brand motor. just six years newer. one is 2000, one is 2006.

2000 - model: 25ELPT4S 172lbs.
2006 - model: F25ELPT 180lbs.

Is this something we can do without involving professionals? I can post any photos if need be. Tips like how and where we disconnect the mess would be helpful... thanks

Thanks much!

 

[lmuss53]

Re: Advice/Tips needed to help us swap out merc 25hp 4strokes on pontoon

Angie, my experience with motor swapping is more with Johnson and Evinrude motors but these motors should be "plug and play" with the controllers. DO NOT start unwiring thing or you'll end up with a nightmare on your hands.

If these motors use the same controller cables and controller wiring harness it is a pretty simple process.

Unhook the hot and ground wires from the battery, don't unhook any other wires yet. Coil them up and zip tie them.

Unhook the fuel line from the motor.

Unhook the steering, by loosening the big nut where the cable goes through the motor, and unhooking the linkage from the end of the cable. You will have to pull the linkage off the motor to swap to the other motor unless they are the same, which they should be. The cable won't slide all the way out until you are lifting the motor off the boat.

Unbolt the motor from the transom (leave one bolt in until the very end).

Pull the cover off and pull the controller cables off the throttle and shifter linkage (mark them). The wiring harness should run from the controller to a junction somewhere and plug into another harness that is part of the motor. You should not have to unwire and rewire much of anything. Find this junction and unplug the motor.

If everything is loose and out of the way lift the motor off and set it aside, sliding the steering cable out as you go, and taking the battery cables with you.

After you do the same thing with the other motor, sit it on the transom and hook everything back up starting with the steering cable and reattaching the power cables last.

If you find that the cables or wiring harness are not the same just swap the controllers too.

Your pics will help the forum members to tell you exactly what you have on your hands.

I've almost certainly left something out, so hopefully some Merc guys will fill in what I missed.

 

[lmuss53]

Re: Advice/Tips needed to help us swap out merc 25hp 4strokes on pontoon

Holy carp Angie I looked at a different sight to see if the parts were compatable and there are like 40 different models of 2006 25 hp Mercs. I didn't even look at the 2000 models. When you post up the pics put the exact model numbers and the serial numbers.

These motors were made by Yamaha at some point in time and then went over to Merc. I am not sure of the exact transition years, that may play into this deal also.

 

[Angie Northern WI]

Re: Advice/Tips needed to help us swap out merc 25hp 4strokes on pontoon

Holy carp Angie I looked at a different sight to see if the parts were compatable and there are like 40 different models of 2006 25 hp Mercs. I didn't even look at the 2000 models. When you post up the pics put the exact model numbers and the serial numbers.

These motors were made by Yamaha at some point in time and then went over to Merc. I am not sure of the exact transition years, that may play into this deal also.

Hello, Thank you for your posts. I will post some pictures later after this downpour lets up. the model numbers are listed in my post.
Angie