Merc 402 40hp?

[onthewater102]

Not at all - I've just found myself too far down the rabbit's hole to get out without realizing it on far too many a project not to ask the questions I wish others around had prodded me with.

 

[user 20022]

Thanks for asking me those questions. I'm just glad to have some feed back on this.

Sent from the dust in front of you!

 

[user 20022]

I figured I'd try to fire the motor before i tore it down and couldn't get any spark. I cut back the wires on the stator and found more corroded wires. Looks like I'll be buying another stator... One more step to reliability. Looks like i might just have more time off the water with this tin than i thought. All i have that works is a 4hp merc And I know that wouldn't push the tin without struggling.

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[JMichael]

I know you've already stated you didn't intend on selling it so care so much what it's worth when you're done. But FYI, I cleaned up, tuned up, and painted this 20 horse of the same vintage and then sold it for $650. With yours being a 40horse, and all that work done to it, I can't imagine it not being worth quite a bit more than what my 20 was.

 

[user 20022]

That 200 looks good man! Im all about reliability. I'm going to do mine in a red and black two tone. It should look real nice once finished.

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[user 20022]

Little by little it's coming apart... I've already broke one exhaust bolt last week. Sucks...



View attachment 1

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[JMichael]

Yea, those pics are looking familiar.



:lol:

 

[user 20022]

Yep that's what mine will look like soon enough lol.

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[nowgrn4]

I assume the gasket set has new top and bottom crank seals?

 

[user 20022]

Yep any seal needed is provided in the kit. Needle bearings and all.

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[user 20022]

And let the scoring begin...

What do you guys think about the scoring?

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[onthewater102]

Just confirmation of what you already knew - compression loss. once you pull the pistons and can take measurements of how deep they run you'll be able to figure if honing/re boring is still an option.

 

[user 20022]

Yep. I should have it taken down completely this weekend.

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[onthewater102]

The scoring was in the cylinder with the lost compression right? At least it lined up with the port opening so you could see it and confirm that as the cause & not that something warped from over heating.

 

[user 20022]

True. I didn't think about it like that. It does look like some trash made its way into the engine.

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[onthewater102]

You did check the lower unit right? Oil is nice & clean & it shifts into fwd gear cleanly & into reverse? Now that you've got it off the powerhead you should be able to tell that the gears turn cleanly too.

 

[user 20022]

Yep the lower end is in great shape. Forward neutral and reverse work smoothly oils good as well.

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[wmk0002]

I'm late to this thread, but I rebuilt my 70hp Force this past summer. It's a 3 cylinder and the machine shop charged me $160 to bore/hone all cylinders plus they pressed out my wrist pins for me and pressed on the upper main bearing on the crank. I think the press work was only $10 and the machine work was $50/cylinder. So for a two cylinder you may be looking at $100 from your local machine shop.

Also, I bought my rebuild kit from https://www.powerheadkit.com/mercury-mariner.htm. They have good customer service and it seemed to be a great deal once you start pricing all of the individual parts off of parts websites.

 

[user 20022]

I'm late to this thread, but I rebuilt my 70hp Force this past summer. It's a 3 cylinder and the machine shop charged me $160 to bore/hone all cylinders plus they pressed out my wrist pins for me and pressed on the upper main bearing on the crank. I think the press work was only $10 and the machine work was $50/cylinder. So for a two cylinder you may be looking at $100 from your local machine shop.

Also, I bought my rebuild kit from https://www.powerheadkit.com/mercury-mariner.htm. They have good customer service and it seemed to be a great deal once you start pricing all of the individual parts off of parts websites.

Hey your not too late. Thanks for the heads up on the parts source. They seem to have more parts for less $$$. I'll give them a call to see what's in the kit compared to the other site I was considering. How was the quality of the parts?

Sent from the dust in front of you!

 

[wmk0002]

I'm late to this thread, but I rebuilt my 70hp Force this past summer. It's a 3 cylinder and the machine shop charged me $160 to bore/hone all cylinders plus they pressed out my wrist pins for me and pressed on the upper main bearing on the crank. I think the press work was only $10 and the machine work was $50/cylinder. So for a two cylinder you may be looking at $100 from your local machine shop.

Also, I bought my rebuild kit from https://www.powerheadkit.com/mercury-mariner.htm. They have good customer service and it seemed to be a great deal once you start pricing all of the individual parts off of parts websites.

Hey your not too late. Thanks for the heads up on the parts source. They seem to have more parts for less $$$. I'll give them a call to see what's in the kit compared to the other site I was considering. How was the quality of the parts?

Sent from the dust in front of you!

I was satisfied with everything it came with. The pistons were Vertex brand which are good quality. I know you can upgrade to Weisco too if you want. Some of the gaskets seemed a little thin but the main ones (the head, exhaust, and spacer plate gaskets) were up to OEM standards.