Doing my own rebuild on a 96 200 EFI

[kell490]

I just got my motor back from the dealer with an estimate of $3400.00 for a rebuild. One cylender overheated and scored. The shop said they would bore .15 over and replace the piston,rings, a new oil pump gear drive. Also replace all the rod barrings beacuse the kit was only $158.00. I have experince with rebuilding 2 cylender Jet ski motors and dirt bike engines. I have the merc service manual, but what should I replace other then what they said if nothing else is damaged. Also is it worth removing the Oil injections and going to pre-mix oil. I have never had problems, but the shop said they really didn't know what caused the rings to score. I think it was running lean because I had problems with old fuel in the tank from not using the boat for a couple of years. Is it bad to have one cylender bored .15 over? wouldn't that cause the motor to be unbalanced?

 

[NEECAPRS]

Re: Doing my own rebuild on a 96 200 EFI

Kell: It sounds like you could do the rebuild yourself just fine. May need some tools for the job that are Merc only. If you know someone who has them and will let you borrow them it can save you a bundle.<br />Don't worry about balance. The new piston is made to the same weight. Besides, these(V-6)motors aren't really balanced anyway. Look at the counterweight arrangement. If they were serious about balancing you'd see counterweights all along the shaft rather than just on the ends.<br />Most important: Find the problem and fix it. Otherwise you'll have trouble again.<br />Take your time; think ahead; and good luck will be yours

 

[ken thrussell]

Re: Doing my own rebuild on a 96 200 EFI

Hi i had a 200 v6 that i rebuilt on my dining room table wife wasn't happy but sure kept everything clean......biggest thing is everything clean and follow your manual i had a seloc one then came by a actual shop manual what one had the other didn't.....as everything was going together i had squirted some 2 stroke oil in all the bearings, replace all seals too, my cause was oil injection failed a nylon gear that drove the pump ,,,,it was premix after that

 

[Chris1956]

Re: Doing my own rebuild on a 96 200 EFI

Kell, $3400 for a rebuild is very expensive. If you query iBoats, I will bet that they will sell you a rebuilt powerhead (6 bored cylinders, 6 new pistons, rod bearings and seals) for about $2500. If you are inclined to do the rebuild yourself (and it sounds like you have the knowledge), I would inspect all the cylinders for scoring and rebore as necessary, lightly hone the non bored cylinders and install new rings on all pistons. The manual will tell you to scrub the block with soap and water to get all the honing debris out of the bores and then oil it up. <br /><br />I always had to disconnect the rods from the crank, install the pistons in the block individually and then use grease to stick the rod bearings into place while "closing" up the rods.<br />It is a tedious process, but I could never figure out another way to do it.<br />Oh yeah, clean the carbs, new water pump impeller, inspect the timing and away you go!