Raw Water Impeller Change 200XL Offshore

[jason78]

Is there an online resource or instructions/steps on how to change the raw water impeller on a '98 200XL 2 Stroke. Serial 0G594313. Not seeing the impeller kit listed on the merc parts website either. Any help would be greatly appreciated! Jason

[JOE54]

i would suguest a fac serv manual,might give EUROPEAN MARINE a cal in am they can fix you up with correct kit and manual,sponsors on here with a wealth info and knowledge of the offshore engine

[jason78]

Thanks Joe! Yes, I was hoping I might hear from Don. He has been a huge help in the past. There seem to be You Tube videos out there but none for my exact model. Not sure how universal they are. I understand the basics of what needs to happen. Mainly want to know any "gotchas", "surprises" or things to know ahead of time. Not sure if the shift shaft is of concern or if gear lube needs to be drained first. Also would like to know what all should be replaced and if there is anything else that should be lubed or serviced while it is apart. Bearings, wear plates, etc. I dont mind spending some extra money on parts to avoid having to tear it down again later. Thanks!! Jason

[leonreno]

Water pump kit should include all the parts for the water pump itself. No bearings to lube or check with water pump replacement. Gearcase lube should be changed once a year, usually done at the end of the fishing season but anytime is good, especially if hasn't been done in awhile. You will need to grease the splines on the shift shaft and the drive shaft, just make sure no grease is on the ends of either shaft. DO buy the service manual, a worthwhile investment for the person doing their own maintenance. Helps me tremendously. Call Don or Rhonda and they will have the pump kit for you by your serial number.

[rickdb1]

Might look through this too..

http://www.bassboatcentral.com/sttips.htm

[EuropeanAM]

Might look through this too..

http://www.bassboatcentral.com/sttips.htm

+1

Only exception- do NOT use any grease on the impeller. Dawn Dish-Soap is a suitable lubricant for installing impellers.

Avoid "tube" videos- many of them are riddled with costly errors.

If you need further assistance:



Mercury - 2.0/ 2.4/ 2.5 Liter High Performance
For discussions related to 2.0/ 2.4/ 2.5L motors (Carb, EFI, Optimax or Racing)

[jason78]

Thanks Everyone!

Don: Is there a water pump kit I should buy or just the impeller? Seems to be pumping fine, just PM. Merc parts catalog does not list a kit but figured you might have a part number. I am new to outboards. Serial is 0G594313

[rickdb1]

Looks like the Mercury part number 96148A5 is the kit according to Don's online site.

[jason78]

Looks like the Mercury part number 96148A5 is the kit according to Don's online site.

Thanks Rick! WOW!!!! 8 O-Rings and 6 gaskets! Whew! Maybe I better find the p/n for the service manual too!

[jason78]

Parts site says I need a 90-824052R2 but quick online searches suggest that may only be a supplement or there might be a newer manual available that includes the supplement. Any suggestions on what the most current manual is for my outboard so I can pick one up?

[BIGFLAT]

Mechanic at the dealer where I got a kit for my '95 Mariner Mag III told me the kit (96148A) fits most all V-6 outboards. I had lots of spare gaskets and O rings left over. My suggestion to you is to carefully remove the parts on yours and lay them out in the order you remove them, and them match up the same parts from the kit. Take your time, and it'll do fine...BF jason, I'm sending you a PM...BF

[EuropeanAM]

Use 96148A8 for a complete kit. It's quite cost-effective, too.

[jason78]

Thanks to everyone and especially BIGFLAT and Don at EM. I got a manual and water pump kit from EM and it arrived the other day. After initial disassembly I have a couple of questions.

1. Is there supposed to be any kind of seal in the space between the top of the impeller insert and the top of the pump cover? See pic below where my finger is.

2. Also in this pic, I'm wondering of the seal for the pump output is pre-installed in the pump? The parts diagram shows a seal between the pump housing and the white water guide pipe. This seal is not loose in the rebuild kit nor does it appear to be on the old pump.

[IMG][/IMG]


3. Is this as far as I should tear this down for regular PM? Or should I remove the base and replace everything under it too? Looks like there are pieces in the kit to do this. Just not sure how necessary it is for PM.

[IMG][/IMG]

Thanks!! Jason

[jason78]

One final question: The manual I purchased has several different lower units listed. The one closest to mine has a Casting Number listed for reference on the diagram of 1647-9147-C2 however mine is a C3. There is no C3 listed in the manual so is it safe to assume the C3 is close enough to the C2 to use it for accurate reference?

[leonreno]

1. The impeller seals to the top of the SS insert, so no seal on the outside, however there is sometimes a rubber ring called a "slinger" that slides down the drive shaft and up against the water pump. Its job is not to seal the pump but to keep any water that comes through from riding up the shaft and hiting the Powerhead and its subsequent bearings.

2. There should be a rubber gasket seal in the tube sticking out of the pump. The copper tube from the Powerhead fits inside and seals into this ring. The white plastic tube that fits into this opening is only a guide to help get the copper tube into the water pump housing when reinstalling the lower unit. It does not seal.

3. On regular water pump changes most people do not replace the base.

[JOE54]

good idea to replace gasket and o ring on base as well as all others gaskets base gaskets bad about breaking at thin area at rear intake area

[jason78]

Thanks for the additional input! So regarding this seal for the water output, I guess this is something I need to order separately? It is #39 in the diagram I posted above. Very strange and frustrating it would not have simply been included in the Merc kit, heck, it even included a replacement guide tube. Any idea what a part number is for this seal?

[leonreno]

Thanks for the additional input! So regarding this seal for the water output, I guess this is something I need to order separately? It is #39 in the diagram I posted above. Very strange and frustrating it would not have simply been included in the Merc kit, heck, it even included a replacement guide tube. Any idea what a part number is for this seal?

It should be already installed in the pump, stick your finger inside the water outlet and you should feel a rubber ring, it will be conical in shape to accept copper pipe and seal to water pump.

[jason78]

It should be already installed in the pump, stick your finger inside the water outlet and you should feel a rubber ring, it will be conical in shape to accept copper pipe and seal to water pump.

Ok, I'll check again. Maybe its already glued in. There is definitely something in there that the white tube goes up against. Hard to tell if it is rubber or not. I was just not sure if it was part of the pump casting itself or a pre-installed component. I guess my confusion was coming in since the pats diagram shows it as a separate part but it appears maybe it is made in to the pump housing. Thanks!

[JOE54]

oem housing/ rubber usually always in there