Re: 2.5L 200 HP rebuild/repair
Inspection/Remeasuring:
After inspecting the pistons a little closer I was able to remove enough unburned carbon to gather some valuable info. Piston's 1,2,3, and 5 are all .030" oversized. Piston 6 is .015" over. After borrowing a 3-4" mic from work I...
Re: 2.5L 200 HP rebuild/repair
"If its a Xri make sure that the recirc nipples/fittings are in place as I have seen a few blocks without them."
I am assuming you are talking about all of the brass check valves? If so I have confirmed that everything that was on the old block is on the new one...
Re: 2.5L 200 HP rebuild/repair
Unfortunately I have finished disassembling the motor. When I took the #4 piston and rod out there was no trace of the rod bearing. It appears that the crankcase, crankshaft, and the block may all be trashed. Here are some pictures (they didn't turn out very...
Re: 2.5L 200 HP rebuild/repair
I just wanted to post some pictures to help illustrate where the powerhead wants to separate. It seems like it would come off easily if I could lift it with the steering arm detached from the cables. Here is where it is lifting:
I've read previous suggestions...
I am rebuilding/repairing (not really sure of the difference at this point since the motor torn apart) my 2.5L 200HP and I know that I will need a lot of guidance from the good people here on the forum. I am still hopeful that this motor can be salvaged but I am needing to get it completely...
I'm looking at buying a used outboard in case my motor is beyond repair or at least too expensive for me to repair. I have found someone selling a 98 Mercury 150 HP EFI for $1500. I have done a compression check and they seemed good. My reservations about this motor are that it hasn't run...
Re: 200 HP Mercury started knocking
Here are some pictures of the motor. I am borrowing a cherry picker to pull the motor tomorrow so I should be able to inspect the crank in the next couple days. Anything specific I should be looking for other than obvious damage?
Re: 200 HP Mercury started knocking
I have disassembled the cylinder head on the side with the damaged piston. The pictures I took show some serious damage with metal chunks everywhere.
I am planning to do the work myself to keep the cost to a minimum. I have the service manual but this...
I have a 93 Mercury 2.5L 200HP carburated outboard on a 90 Ranger 391V. The motor was running fine for three months then two weeks ago while running to a spot in a bass tourny the motor started to knock. I shut it down immediately only starting it one more time to try to detect where the noise...
I am new to the forum so please forgive me if this is a simple fix or a common problem. I recently purchased a used bass boat with a 200 Mercury 2.5L motor. The steering became difficult so upon inspection I noticed the steering cable mounting bracket was bent from trimming the motor up when...
