rebuilding merc 200 efi, how hard

[zuup_2000]

My buddy burned up a piston in his 96 merc 200 efi. My question is, how hard is it to rebuild the powerhead. I have grown up rebuilding automobile engines(even some Reher morrison racing engine school), and Ive rebuilt my share of small 2 stroke engines, but I have never touched an outboard. A tech at a marina told me to not even try, and that it was too hard. <br /> I cant see how it would be all that different from anything else ive seen. I figured a good repair manual would help with certain things.<br /> Are there any specialty tools I will need to get, or is this harder than Im thinking it is.<br /> Also, if it is do-able, where is a good place to get pistons, rings, and other parts we may need.<br /> From what we can figure out, he lost the oil injection, and it overheated before he heard the alarm go off.<br /> thanks, Mike

 

[ZmOz]

Re: rebuilding merc 200 efi, how hard

The tech at the marina wants you to let him do it so he can make a grand. If you can rebuild a car engine you can rebuild an outboard. It's slightly different than a car but not much. A good repair manual and this forum should be all you need.

 

[andrewkafp]

Re: rebuilding merc 200 efi, how hard

ZM<br /><br />Like yours ?<br /> http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&category=50439&item=2459374273

 

[ZmOz]

Re: rebuilding merc 200 efi, how hard

Originally posted by Redhull:<br />ZM<br /><br />Like yours ?<br />http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&category=50439&item=2459374273

Almost exactly...why?

 

[andrewkafp]

Re: rebuilding merc 200 efi, how hard

Well they say it's a 78 and yours is a 74 ?<br />Looks the same..<br />Is is a good price ?

 

[ZmOz]

Re: rebuilding merc 200 efi, how hard

Originally posted by Redhull:<br />Well they say it's a 78 and yours is a 74 ?<br />Looks the same..<br />Is is a good price ?

Yeah, here's a pic of my '74.<br /> http://zmoz.com/wake.JPG <br />I think they did change the cowling by '78, but that motor could just have the cowl from an older one. I'm only paying $400 for the replacement I'm getting, that one will probably go for a good bit more.

 

[andrewkafp]

Re: rebuilding merc 200 efi, how hard

Good luck..<br /><br />Hope Ur back on the water soon...

 

[zuup_2000]

Re: rebuilding merc 200 efi, how hard

Originally posted by ZmOz:<br />The tech at the marina wants you to let him do it so he can make a grand. If you can rebuild a car engine you can rebuild an outboard. It's slightly different than a car but not much. A good repair manual and this forum should be all you need.

I kind of figured that he just wanted me to let him do the work. He kept saying "just bring it in to me, Ill get ya fixed up". He wouldnt even give me any answers to my questions about why its so difficult. <br /> Besides a torque wrench, and basic hand tools, what kind of specialty tools will I need?<br /> Will I need a torque to yield setup, or are they ft.lbs. and inch lbs. on the main fasteners.<br /> Thanks for the reply, and any other info will be appreciated. Im sure I will be on here with questions when it comes time for the rebuild.

 

[robalofish]

Re: rebuilding merc 200 efi, how hard

First - GET A MANUAL <== not yelling just emphasizing, my preference is for the one from Mercury, I have all 3 for my 200hp, what one shows or doesn't the other might.<br /><br />Second - Read a lot on this site about frozen fasteners you will have some.<br /><br />Good Luck and post with your questions there’s a lot of good help here.<br /><br />FRish >()>

 

[Clams Canino]

Re: rebuilding merc 200 efi, how hard

And use a digital camera A LOT. It helps get all the unfamiliar "spaghetti" back in the right places.<br /><br />-<br />W