Rebuild or what?

[.44mag]

Tore hell out of it didnt it. Possibly the side pin in the piston (pin that holds ring from spinning) came out and got the port or came out and ring spun and caught port? Looks like it all started from heat , can't really tell but kinda looks like leaned out. Joe can prob tell u better from looking at it. The bearing wasn't the cause , everything came apart after sumthin hooked the port

Can u take a pic of top of piston and also the 2 pins by the rings , I can see 1

Here you go. Yeah I used a screw to get the piston out.
20200831_185855.jpg

20200831_185829.jpg

20200831_185817.jpg

The hole is where we drilled the first time.

[.44mag]

Tore hell out of it didnt it. Possibly the side pin in the piston (pin that holds ring from spinning) came out and got the port or came out and ring spun and caught port? Looks like it all started from heat , can't really tell but kinda looks like leaned out. Joe can prob tell u better from looking at it. The bearing wasn't the cause , everything came apart after sumthin hooked the port

Can u take a pic of top of piston and also the 2 pins by the rings , I can see 1

Here you go. Yeah I used a screw to get the piston out.
20200831_185855.jpg

20200831_185829.jpg

20200831_185817.jpg

The hole is where we drilled the first time.

[.44mag]

If they are blurry sorry for that, old tablet. The pins were still there.

[Merc2.4]

If those pins r still there then idk y it would have hung the port , maybe joe can shed some light on it

[JOE54]

Attachment 422458[ATTACH=CONFIG]4Attachment 42246122459[/ATTACH]Attachment 422460Attachment 422462

Well found all of this. Number one. Bearing failure cause this?

posibly , dout it , why did bearn fail (lean ) maybe condition of fuel system includ injex /detonation hammer brng possible / operating at high temp verg of over heat all things to consider

[.44mag]

posibly , dout it , why did bearn fail (lean ) maybe condition of fuel system includ injex /detonation hammer brng possible / operating at high temp verg of over heat all things to consider

I did have over heat issues before all this happened, I got it straightened out and it ran fine for 3 or 4 trips prior to going boom. After it went boom I called the guy I bought it from, who retracted his statement about having it rebuilt and stated that it it had been stiiting up for 6 years. So possibility a combination of heat and that injector going lean. I'm guessing don't know. Any way my wife went and got me a power head to replace it. Just gotta get time to put it on. So I will

[Merc2.4]

You will definitely need all new electronics and fuel system went thru , just what will have to be done since cant point out the smoking gun. Jmo

[JOE54]

good wife too ,keeper

[.44mag]

You will definitely need all new electronics and fuel system went thru , just what will have to be done since cant point out the smoking gun. Jmo

A complete power head, turn key, all new cdi electronics and such.

[.44mag]

good wife too ,keeper

Yes sir she is

[.44mag]

Well got the power head swapped, all new electronics and fuel line, bulb and of course filter. Was only able to crank it up on the muffs, wont be off till Thursday to run it. 119 at the stats idling, yeah I know hose water. But boy this thing even fires up quicker, lol.

[.44mag]

good wife too ,keeper

Joe the tilt trim motor stopped working. The new power head came with relays and is a two wire trim system, blue and green. The one on my boat is a three wire, green, blue, and black. I have a mid section that has a two wire motor but the base is flat and wont engage the pump on my trim pump. If I get a new motor can I make the three wire system work with the two wire relay sytem by putting the ground wire on the blck some where? Or would it just beter to swap out the entire motor, pump and ram cylinders while I have the outboard off again? The three wire goes to the serial number in my signature. The two wire thats one the mid section and lower unit that I have in my shed came off of a 2000 to 2001 mecury 200 (don't have that serial number unfortunately just know that it has the same lower unit as mine but newer).

[JOE54]

swap systems put 2 wire system on where 3 wire is itll fit theyre better mtrs anyway

[.44mag]

Ok Thanks

[.44mag]

swap systems put 2 wire system on where 3 wire is itll fit theyre better mtrs anyway

Ok finally got the tilt trim pump swapped out, seems faster than the other one (the three wire). So good there. Would the electronics, as far as coils, stator, trigger and power packs be ok from the blown power head? Thinking about keeping them as spares. Before the blown engine deal the electrical parts seemed to be in good running order. Also would it be a good idea to run Don's cocktail in a one or two gallon can of premix at a stronger dose to ensure that the injectors on the newer power head are clean? Or use a whole bottle of sea foam withba gallon of premix then a gallon of premix and cocktail? I'm about at my budget, lol, for the power head swap and want to get everything right before I start running it. Don't have a serial number for the newer power head but it has side electrode spark plugs in it, should I go back with those or would the BU8H surface gaps be fine to run. The newer power head came from a 2001.

[JOE54]

01 should have cdm ign not the same as 96 model ,so naaa on that, cocktail in couple gal should be fine

[HellaBass]

Based on my research this spring, I think you are better off just ordering a remanufactured powerhead and replacing. I have a 2005 200 EFI Merc and rebuilds may not actually save you money with the increased labor and it takes much longer.

[.44mag]

Based on my research this spring, I think you are better off just ordering a remanufactured powerhead and replacing. I have a 2005 200 EFI Merc and rebuilds may not actually save you money with the increased labor and it takes much longer.

I swapped a different power head on to it.

[.44mag]

swap systems put 2 wire system on where 3 wire is itll fit theyre better mtrs anyway

Ok this new power head. Compression on warm engine, 5 cylinders at 119 psi 1 at 118 psi. Temp readings at thermostats and close to all spark plugs were between 135 and 130 degrees. It will jump on plane and run fine one trip and bog out the next trip barely getting over 2000 rpms. While it is bogging out it will fluctuate like it's trying to gain rpms. Found two cdm's (or coils) not responding. Replaced them. Boat ran fine for one trip after that then back to the same thing. Two more cdm/coils act like they're not responding possibly a slight change. Plugs are black and wet to the touch. Haven't found a burnt wire connection or bad ground or should say nothing jumps out at me. Should I check the modules on the starboard side and or the stator and trigger next? What about the two boxes on the top and port side?

[.44mag]

20201014_153822.jpg20201014_153817.jpg

Had the timing adjusted before all this, noticed this on the throttle adjustment, is that correct? I thought those stop screws should be almost touching the stops?