Mercury 200 EFI User Manual

4
A
POWERHEAD
90-883728 JULY 2001 Page 4A-1
POWERHEAD
Section 4A - Powerhead
Table of Contents
Specifications 4A-2. . . . . . . . . . . . . . . . . . . . . . . . . . .
Block 4A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reed Valve Opening 4A-2. . . . . . . . . . . . . . . . . .
Cylinder Bore 4A-2. . . . . . . . . . . . . . . . . . . . . . . .
Piston 4A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 4A-3. . . . . . . . . . . . . . . . . . . . . . . . . . .
Powerhead Repair Stand 4A-4. . . . . . . . . . . . . .
Notes: 4A-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Block Assembly 4A-6. . . . . . . . . . . . . . . . .
Exhaust Manifold and Exhaust Plate 4A-8. . . . . . .
Crankshaft, Pistons and Connecting Rods 4A-10. .
Cylinder Head 4A-12. . . . . . . . . . . . . . . . . . . . . . . . . .
Bleed System Routing 4A-14. . . . . . . . . . . . . . . . . . .
Torque Sequence 4A-16. . . . . . . . . . . . . . . . . . . . . . .
General Information 4A-17. . . . . . . . . . . . . . . . . . . . .
Powerhead Removal from Driveshaft
Housing 4A-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing Engine Components 4A-24. . . . . . . . . . .
Removing Engine Components
Individually 4A-24. . . . . . . . . . . . . . . . . . . . . . . . . .
Removing Engine Components as an
Assembly 4A-25. . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Coil Plate and Harness Removal 4A-27
Starter Motor 4A-28. . . . . . . . . . . . . . . . . . . . . . . .
Electrical Plate Removal 4A-29. . . . . . . . . . . . . .
Oil Pump 4A-30. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Plenum 4A-31. . . . . . . . . . . . . . . . . . . . . . . . . .
Powerhead Disassembly 4A-32. . . . . . . . . . . . . . . . .
Water Pressure Relief Valve Components 4A-41
Torque Specifications 4A-41. . . . . . . . . . . . . . . . .
Cleaning and Inspection 4A-42. . . . . . . . . . . . . . . . . .
Cylinder Block and Crankcase Cover 4A-42. . .
Special Service Information 4A-42. . . . . . . . . . . .
Cylinder Bores 4A-43. . . . . . . . . . . . . . . . . . . . . . .
Pistons and Piston Rings 4A-44. . . . . . . . . . . . . .
Cylinder Heads and Exhaust Divider Plate 4A-45
Crankshaft 4A-46. . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft (and End Cap) Bearings 4A-46. . . .
Reed Block Assembly 4A-47. . . . . . . . . . . . . . . . .
Reed Block Housing 4A-48. . . . . . . . . . . . . . . . . .
Connecting Rods 4A-48. . . . . . . . . . . . . . . . . . . . .
Powerhead Reassembly and Installation 4A-51. . .
General 4A-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Installation 4A-55. . . . . . . . . . . . . . . .
Piston and Connecting Rod Reassembly 4A-57
Piston and Piston Ring Combinations 4A-58. . .
Piston Installation 4A-59. . . . . . . . . . . . . . . . . . . .
Crankcase Cover Installation 4A-62. . . . . . . . . . .
Reed Block Assembly 4A-64. . . . . . . . . . . . . . . . .
Assembly of Reed Blocks to Intake
Manifold 4A-64. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly of Exhaust Divider Plate to
Block 4A-64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection 4A-66. . . . . . . . . . . . . . . . . .
Cylinder Block and Crankcase Cover 4A-66. . .
Reinstalling Engine Components 4A-68. . . . . . .
Notes: 4A-69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Lever and Shift Shaft 4A-70. . . . . . . . . . . . .
Powerhead Installation On Driveshaft
Housing 4A-74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Break-in Procedure 4A-81. . . . . . . . . . . . . . .
Gasoline/Oil Break-In Mixture 4A-81. . . . . . . . . .
Break-In Procedure 4A-81. . . . . . . . . . . . . . . . . . .

Mercury 200 EFI Specifications

General

Brand	Mercury
Model	200 EFI
Category	Engine
Language	English