Topic: 1995 200 XRI

This topic has 4 replies, 4 voices, and was last updated 17 years ago by Bass Cat Boats.

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June 5, 2009 at 9:48 pm #256079

egarrigus
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I HAVE A 1995 MERCURY 200XRI AND I BROKE THE LOWER UNIT,MY BUDDY HAS A LOWER UNIT OFF A 1989 MERCURY 200 BLACK MAX,WILL HIS LOWER UNIT WORK FOR ME IT LOOKS LIKE IT WOULD BOLT RIGHT UP.AND ALSO WHAT IS THE PURPOSE OF PLUGGING THE TOP THREE HOLES OF THE WATER INTAKE.

June 5, 2009 at 9:53 pm #256080

oldtimer57
Participant

You really need a merc dealer to look this up. Chances are good it will work, but around 1992 the 2.4 was replaced by the 2.5 block. I dont know that there was a difference, but a small difference in the driveshaft length would not be obvious, but could cause problems. Generally we plugged the upper holes to prevent them from sucking in air when the motor height is fairly high. If you have half the holes covered with water, and half exposed to air, the air is easier to move, and you lose water pressure by sucking in air. Plugging the upper holes helps to prevent this. There are also small “scoops” you can add that cover the holes with a scoop opening facing forward to grab water and force it into all the holes, if pressure becomes an issue.2008 Pantera Classic2014 Mercury Pro XS 200

June 6, 2009 at 3:17 am #256081

aceman93
Participant

I suggest plugging the top three holes only if you are running your motor high enough to lose water pressure at full throttle or close to that. Oldtimer was right on the money. I had a buddy that also put bondo over the plugged holes but I dont know if this added any to performance at all but it looked a but better than having hex head screws in the holes.

June 6, 2009 at 3:55 am #256082

Bass Cat Boats
Keymaster

It really doesnt add anything, as if the plugs are needed, it is because the holes are out of the water anyway. The main thing is to find stainless set screws, so that you dont end up with a rusty-looking mess. If you want the neatest possible fix, insert the set screws with locktite, run them just down below the surface, then clean it up and cover with marine tex and then finish it by sanding, priming and sanding to completely make the holes go away. Yet they are always within easy reach if you want to get them out…2008 Pantera Classic2014 Mercury Pro XS 200

June 6, 2009 at 4:08 am #256083

Bass Cat Boats
Keymaster

If you put Stainless plugs in as OT57 suggested, the plugs can be tipped black and will look good with the allen heads showing without the finishing.
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