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include sealers &
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That motor's 7 years old.
Part is no longer available.
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MERCURY & U.S. MARINER OUTBOARD POWERHEAD KITS

PARTS PACKAGES FOR REBUILDING POWERHEADS

These kits contain all the parts you will commonly need to complete the overhaul of your outboard's powerhead. If the determination has been made that you need to rebuild, we have the necessary items! And the nice part is, you will pay less for the kit than you would for the individual parts, as you save us time in ordering. So you will have all the goodies you need to do the job right.

For motors not listed, and motors under 20 HP contact me directly for the specific application. It is likely I can provide the components you need. Feel free to call about your motor or purchasing any components of these kits.


UNLIKE MANY OF OUR COMPETITORS, OUR rebuild kits include ALL of the following items, as required, unless noted:

  • PISTONS/ RINGS/ WRISTPINS/ RETAINERS
  • COMPLETE GASKET & SEAL KIT
  • CRANKSHAFT MAIN BEARINGS
  • CONNECTING ROD LARGE & SMALL END BEARINGS
  • CONNECTING ROD BOLTS
  • GASKET SEALING COMPOUNDS AND CRANKCASE SEALER
  • TECHNICAL ASSISTANCE FROM THE MASTERTECH !

 

WISECO PISTONS AVAILABLE FOR MANY KITS AT HIGHER PRICE.
HOW TO ORDER

Look for the basic manufacturer and horsepower on the table below, click the appropriate box to go to that area. Then, just add the kit you need to the shopping cart.
BE SURE and submit THE MODEL and SERIAL NUMBER as well as the PISTON OVERSIZE information in the special instructions area of the order form.

warning symbolNOTE!! I reiterate, you MUST PROVIDE THE MODEL and SERIAL NUMBER as well as the PISTON OVERSIZE when ordering.
I cannot send you the correct parts otherwise!


Many prices have changed recently; we haven't had time to go thru all of these and re-figure them.
Prices are a general guide only. Please contact us for current prices

PRICES ARE REPRESENTATIVE ONLY! PLEASE CONTACT US IF YOU HAVE ANY QUESTIONS.


3 & 4-CYLINDER SPORT JET SEE FORCE LISTING



MERCURY 2-3 Cylinder Kits to 70 HP
Please remember to enter your
SERIAL #  and any OVERSIZE REQUIRED in the shopping cart !!

OVERSEAS CUSTOMERS: SHIPPING 2 & 3 CYLINDER KITS IS $80 SHIPPING BY PRIORITY MAIL
20-25-20JET HP
2 CYL 2.562" BORE
NOT FOR MARATHON/SEAPRO
STD., + .020, .030, .040 $490.00

Series 100-04-1x

30-40 HP 1994-07 2-cyl STD., +.015, .030 $467.00
35 HP 84-89
40 HP 72-83
STD., +.015, .030
NOTE: top main no longer available
$371.00
50, 60 HP 3 cyl 84-90
70 HP 1977-83
Crossflow
STD., +.010, .020, .030, .040
Mercury  3-cyl 50-70 HP Crossflow
Click Image For Larger
$592.00
Series 100-15-1x
40 HP 1997-07
50, 60 HP 1998-05

3-cyl Motors
STD., +.010, .015, .020, .030, .040
Mercury  3-cyl 50-60 HP 98-05
Click Image For Larger
$651.00
Series 100-06-1x
50, 55, 60 HP 3 cyl
1991-97
Loop charge
STD., +.010, .020, .030, .040
Mercury  3-cyl 50-60 HP 91-97
Click Image For Larger
$650.00
Series 100-07-1x
65 HP 73-76
Crossflow
USING Low Dome Pistons
STD., +.020, .030, .040
WISECO pistons
No Rod Bolts Available
Standard cast piston kit $674.00 on request
$539.00
3 & 4 Cyl: Top or bottom guided rod??
You can ID these by looking at the forging number on the rod. TOP GUIDED is # 646-81884.
BOTTOM GUIDED is # 638-85321

Please remember to enter your
SERIAL #  and any OVERSIZE REQUIRED in the shopping cart !!

OVERSEAS CUSTOMERS:
SHIPPING 4-CYLINDER KITS IS $110 SHIPPING BY PRIORITY MAIL
Classic Inline 4
50 HP 70-85
45 HP 86-89
40 HP 90-97
STD., +.010, .020, .030, .040
"Mercury Classic 4" 40-50 HP
Click Image For Larger
$545.00
Series 100-05-1x
70 HP 87-89
75 HP 90-91
80 HP 87-89
85 HP  87-91
90 HP 87-91
3 cyl looper
Bottom guided rod
STD., +.010, .020, .030, .040
Mercury 3-cyl Looper 70-90 HP 87-91
Click Image For Larger
$728.00
Series 100-25-1x
75 HP 84-86
80 HP 68-83
85 HP 73-77
4 cyl crossflow
STD., +.010, .015, .020, .030, .040 $719.00
75, 90 HP
92-93 3 cyl looper
Top guided rod
STD.,+.010, .020, .030, .040
Mercury3-cyl Looper 92-93 70-90 HP
Click Image For Larger
$766.00
Series 100-35-1x
75 HP 94-07
90 HP 94-07
3 cyl loop charge
Top guided CARB Motors
STD.,+.010, .015, .020, .030, .040
Mercury3-cyl Looper 94-UP 70-90 HP
Click Image For Larger
$766.00
Series 100-40-1x
75 HP
90 HP
115 HP
3 cyl DFI Motors
STD.,+ .015, .030, .040
Mercury3-cyl  1.5L DFI
Click Image For Larger
$975.00
Series 100-27-1x
100, 115, 125 HP
89-91 Inline 4 cyl looper
Bottom guided rod
3.375" Bore
STD., +.010, .020, .030, .040
Mercury IL4 thru 1991
Click Image For Larger
$983.00
Series 100-25-2x
100, 115 HP
92-93 Inline 4 cyl
Top guided rod
STD., +.010, .020, .030, .040
Mercury IL4 1992-93
Click Image For Larger
$1,008.00
Series 100-35-2x
115, 125 HP 4 cyl Inline
("L4") 94 up
Top guided rod
STD.,+.010, .015, .020, .030, .040
Mercury IL4 1994-up
Click Image For Larger
$1,008.00
Series 100-40-2x
Mercury 6 Inline, 90-150 HP
Please remember to enter your
SERIAL #  and any OVERSIZE REQUIRED in the shopping cart !!

OVERSEAS CUSTOMERS: SHIPPING 6-CYLINDER KITS IS $120 SHIPPING BY PRIORITY MAIL
90 HP 78-87
115 HP 70-88
135 HP 70-71
140 HP all
150 HP 73-78
100 C I D crossflow
"High dome" piston
INLINE 6
STD., +.010, +.020, +.030, +.040
Regular cast low dome pistons

These kits include rod bearing needles only. Caged bearings available at extra charge

Wiseco pistons also available in .020, .030, & .040 at roughly $995.00 (see note)
$825.00

NOTE: May Vary Depending on Availability and options
Mercury V6 Kits 2.0, 2.4, 2.5 Litre
Please remember to enter your
SERIAL #  and any OVERSIZE REQUIRED in the shopping cart !!
Due to the many powerhead changes on the V6 Mercs, THIS INFORMATION IS IMPERATIVE!!

OVERSEAS CUSTOMERS: SHIPPING V6 KITS IS $120 SHIPPING BY PRIORITY MAIL
You may CONTACT US for Applications, Mercury made many variations of these motors
Top or bottom guided rod??
You can ID these by looking at the forging number on the rod. TOP GUIDED is # 644-818141
BOTTOM GUIDED is # 636-8118
this for V6 MODELS (except 3.0L) only.
Please remember to enter your SERIAL #  and any OVERSIZE REQUIRED in the shopping cart !!
135 & 150 HP 81-91
2.0 litre
(Bottom guided rod
stamped 636-8118
)
Vertical reeds 3.125" Bore
PISTONS with anti-friction
moly-coated coated skirts
STD.,+.010, .020, .030, .040
Mercury V6 2.0L Bottom Guided thru 1991
Click Image For Larger
$1,077.00

Series 100-50-1x

135 HP 2.0L 1991 ONLY PRO-V PISTONS
STD., +.015, .030
$1,139.00
135 HP 92-05
150 HP 92-00
2.0 litre CARB Motors
(Top guided rod
stamped 644-818141
)
Horizontal reeds, pinned heads
PISTONS with anti-friction
moly-coated coated skirts
STD.,+.010, .020, .030, .040
Mercury V6 Horiz Pinned 2.0L Top Guided
Click Image For Larger
$1,165.00

Series 100-30-1x

150 XR4, MAGNUM II
2.4L 1988-91

Pistons and Center Mains
NO LONGER MADE
PISTONS with anti-friction
moly-coated coated skirts
STD size Chrome Bore

NO LONGER AVAILABLE
---  
V6 2.5L litre CARB Motors
(Top guided rod)
Head gasket type
STD.,+.010, .020, .030, .040
Mercury V6 Horiz Carb 2.5L Top Guided
Click Image For Larger
$1,215.00

Series 100-20-3x

135 - 175 HP
DFI 2.5L 3.500" bore
The pistons and gasket set are only difference between this kit and the next.
Pistons will be Wiseco branded in this kit. Please make sure whether yours has o-rings or gaskets
For the most part, serials lower than 0G960500 will have gasket type heads

head gasket type

STD., +.015, .030, .040
Mercury V6 2.5L Optimx w/O-ring Heads
Click Image For Larger
$1,520.00
Custom Kit
135 & 150 HP
DFI 2.5L 3.500" bore
O-ring type heads,
serials 0G960500 and higher

O-RING type

STD., +.015, .030
Mercury V6 2.5L Optimx w/O-ring Heads
Click Image For Larger
$1,245.00
Series 100-49-1x
200 HP, 1991 ONLY
2.5 litre
STD., +010, .015, .020, .030, .040 $1,279.00
2.5L V6 EFI MOTORS
Gasket Heads
STD., +010, .015, .020, .030, .040
Mercury V6 Horiz EFI 2.5L Top Guided
Click Image For Larger
$1,215.00
Series 100-20-1x
2.5L V6 CARB MOTORS
Gasket Heads
STD., +010, .015, .020, .030, .040
Mercury V6 Horiz Carb 2.5L Top Guided
Click Image For Larger
$1,215.00
Series 100-20-3x
2.5L V6 CARB MOTORS
O-RING Heads
STD., +010, .015, .020, .030, .040
Mercury V6 Horiz Carb 2.5L O-ring Type
Click Image For Larger
$1,225.00
Series 100-20-4x
2.5L V6 EFI MOTORS
O-RING Heads
STD., +010, .015, .020, .030, .040
Mercury V6 Horiz EFI 2.5L O-ring Type
Click Image For Larger
$1,225.00
Series 100-20-2x
OPTIMAX 2.5L DFI
3.500" Std Bore

(O-RING type) thru
serial 0T178499

SINGLE ROLLER Center Main Bearing

STD., +.015, .030, .040

Mercury V6  2.5L Optimax Big Bore
Click Image For Larger
$1,239.00
Series 100-28-1x
200 HP 78-90
225 HP 80-81
2.4 litre CHROME BORE

Pistons and Center Mains
NO LONGER MADE
Kits are STANDARD BORE only! Oversizes require re-sleeving at additional cost.
This is a chrome bore motor.

NO LONGER AVAILABLE
----  
Mercury V6 Kits 3.0
Please remember to enter your
SERIAL #  and any OVERSIZE REQUIRED in the shopping cart !!
IMPORTANT NOTE:
There was a change in the lower crank bearing cap. If your original is a 1-piece single seal cap, it must be replaced with the upgraded 2-seal cap, $125.00 additional, as per factory service bulletin. Do not re-use the single-seal cap!

OVERSEAS CUSTOMERS: SHIPPING V6 KITS IS $120 SHIPPING BY PRIORITY MAIL
OPTIMAX 3.0L DFI
3.625" Std Bore
SINGLE ROLLER Ctr Mains
Round pocket pistons

(O-RING type) from
serial 0T178500

STD., +.015, .030, .040

Mercury V6  Optimax o-ring round pocket
Click Image For Larger
$1,410.00
Series 100-48-1x
OPTIMAX 3.0L DFI
3.625" Std Bore
DOUBLE ROLLER Ctr Mains
Round pocket pistons

(O-RING type)

STD., +.015, .030, .040
Mercury V6  DFI o-ring round pocket double roller
Click Image For Larger
$1,485.00
Series 100-48-2x
OPTIMAX 3.0L DFI
3.625" Std Bore
SINGLE ROLLER Ctr Mains
OVAL pocket pistons

(O-RING type)

STD., +.015, .030, .040

Mercury V6  Optimax o-ring oval pocket
Click Image For Larger
$1,410.00
Series 100-47-1x
3.0L CARB/EFI
3.625 STD Bore
STD.,+.010, .020, .030, .040
SINGLE ROLLER Center Mains
$1,405.00
Series 100-45-2x
3.0L CARB/EFI
3.625 STD Bore
STD.,+.010, .020, .030, .040
DOUBLE ROLLER Center Mains
$1,470.00
Series 100-45-1x
Mercury V6 SPORT JET KITS
Please remember to enter your
SERIAL #  and any OVERSIZE REQUIRED in the shopping cart !!
OVERSEAS CUSTOMERS: SHIPPING: ALL V6 KITS $120 SHIPPING BY PRIORITY MAIL
Top or bottom guided rod??
You can ID these by looking at the forging number on the rod. TOP GUIDED is # 644-818141
BOTTOM GUIDED is # 636-8118
this for V6 MODELS (except 3.0L) only.
Please remember to enter your SERIAL #  and any OVERSIZE REQUIRED in the shopping cart !!
175 Sportjet Carb
    with head gaskets
STD.,+.010, .015, .020, .030, .040 $1,329.00
Series 100-20-5x
175 Sportjet Carb
    with head o-rings
STD.,+.010, .015, .020, .030, .040 $1,320.00
Series 100-20-5x
200 DFI 2.5L SportJet STD.,+.015, .030, .040 $1,245.00
Series 100-49-2x
210 SportJet Carb STD.,+.010, .015, .020, .030, .040 $1,321.00
Series 100-20-7x
240 SportJet STD.,+.010, .015, .020, .030, .040 $1,298.00
Series 100-21-8x
250 SportJet DFI STD.,+.015, .030, .040 $1425.00
Series 100-47-2x
DON'T SEE WHAT YOU NEED? JUST ASK.
QUICK QUOTE FORM
QUICK SECURE ORDER FORM

We pay the freight out in USA on all orders over $100.00. Orders less than this amount will have a shipping and handling charge of $8.75 added. Some bulky and heavy items will incur additional charges. You will be notified beforehand if this is the case. Remember, all orders receive free technical support from the MasterTech!


 
 

Please review our Warranty, Returns & Refunds policies before you place an order.

DISCLAIMER

The information provided on these pages is correct to the best of my knowledge, however the MasterTech makes no warranty, express or implied, regarding the use of, results of, or liability created from, application of this data. This information is disseminated in good faith, however MasterTech assumes NO LIABILITY whatsoever in regard to this service. The information, software, products, and services published on this web site may include inaccuracies or typographical errors. Changes are periodically added to the information herein. Mastertech may make improvements to this site at any time. Parts ordered from this website may or may not be in dealer stock at the time of order. Thank you for reading.