1996 Merc 200CXL-wanting cooling schematic

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brianmck

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Nov 16, 2011
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I just had my 1996 Mercury 200CXL 2 stroke rebuilt(block and heads) but when i got it back there was some tubes not hooked up:facepalm: and now no water comes out peehole(only ran it for short spell). All the tubes and hoses seem like they are messed up and don't reach where they should.
Does anyone have a schematic about this? or pics?
serial# is OG325464
thanks!!
 
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carholme

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Re: 1996 Merc 200CXL-wanting cooling schematic

Your engine comes up as a model:

1200425SD MERCURY 1996 200

Parts listing:

http://www.crowleymarine.com/mercury-outboard/1678.cfm

Service Manual P/N: 90-824052R3

http://1manual.com/Mercury manuals/Service Manual PDFs/TwoStroke/824052r3/cover.pdf

You must have Adobe Acrobat reader installed to use this manual. If you scroll down to the lower part of the opening page, you will see the various engine components in red. Click on the one you want and when the first page opens, click on the "Save As" icon at the top LH corner of the page and you can save it to your computer.

If you have a look under Section 4B, "Cooling", page 4B-3/4 you will see the cooling schematic.

Gerry
 
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brianmck

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Re: 1996 Merc 200CXL-wanting cooling schematic

thanks a ton Gerry, I'll check it out asap!
 
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Chris1956

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Mar 25, 2004
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Re: 1996 Merc 200CXL-wanting cooling schematic

Brian, A lot of those V6 motors have the thermostats upstream of the telltale. Untill the thermostats open, no water will emerge from the telltale. Sometimes when running it on a hose, the 'stats will never open. Look for water exiting the gratings above the antiventilation plate and thru the prop.
 
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brianmck

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Re: 1996 Merc 200CXL-wanting cooling schematic

Chris, I run a jet on mine. sorry but what/where is telltale?
thanks!
 
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Chris1956

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Mar 25, 2004
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28,910
Re: 1996 Merc 200CXL-wanting cooling schematic

Brian, There should be hoses connected to the thermostat covers. On a lot of models these are connected together with a tee and then connect to the telltale outlet on the rear of the bottom cowling. BTW - Telltale is proper name for pee hole

Even on a jet, I would think some cooling water would exit the jet unit.
 
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