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-   -   502 496 500hp 525 540 most reliable power (https://www.offshoreonly.com/forums/general-q/375286-502-496-500hp-525-540-most-reliable-power.html)

hogie roll 04-04-2022 10:44 AM

If I had to make up a rating it would be
1a. 502 mag
1b. 496
2. 500 efi
3a. 525
3b. 520-565

I suspect the 520-565 have the 525 cam so valvetrain life would be similar. But mercs seems to have cut cost in the bottom end of the 520-565. Maybe the new machining processes of the 520-565 helps them, but they just haven’t sold enough to have a great idea how they last compared to 525s. 520s at least have cast exhaust manifolds, which helps a lot.

Griff 04-04-2022 01:20 PM


Originally Posted by 1MOSES1 (Post 4827653)
griff I’ve been meaning to ask this question…agree on need to refresh top ends on blue motors every 300 hours. the stock springs are prettty weak. Coupled with junk head gaskets…it’s probably a good idea.

what I don’t understand is rebuilding a bottom end on a 500efi at 600 hours. Everything is more stout than say a 496 and it has a lower compression ratio. Why do black motors get a 1000 hour pass but we say blue motors need a full refresh at 600?

It will depend on the condition of the bottom ends and they could probably go until the 900-1000hr range. Many people will just elect to do the full rebuild instead of waiting for the 3rd top end refresh cycle.

Brad Christy 04-04-2022 06:34 PM


Originally Posted by 1MOSES1 (Post 4827668)
i personally wouldn’t consider carb power in todays day in age. The fuel consumption alone is enough to make the decision.

with that being said fuel injection idle better, run better, etc.

Moses,

Start easier....

Thanks. Brad.
(937)545-8991

SB 04-04-2022 07:19 PM


Originally Posted by hogie roll (Post 4827683)
Supposedly the 496 passed mercs 100hr peak tq to peak power endurance test.

I don’t really have a dog in this fight, but I do think Merc racing’s valvetrain service interval is ridiculously short. The 500efi with its milder cam seems to last a lot longer than a 525

500efi exhaust lobe is the 525efi’s intake lobe. :)

I’ll put $50 down that 525efi owners are heavier on the throttle. I never looked into it, but wonder how different the spring rates are, if they are.

hogie roll 04-04-2022 07:29 PM


Originally Posted by SB (Post 4827752)
500efi exhaust lobe is the 525efi’s intake lobe. :)

I’ll put $50 down that 525efi owners are heavier on the throttle. I never looked into it, but wonder how different the spring rates are, if they are.

And an exhaust valve is much lighter. Unserviced 500s seem to make 800-1000 hrs. 50-100% more than a 525

jeff32 04-04-2022 08:09 PM

Broke a valve on my 500 efi close to 900 hours
the other 2 engines had 1100-1200 hours untouched and still ran fine, but rebuilt them anyways

SB 04-04-2022 08:35 PM


Originally Posted by hogie roll (Post 4827753)
And an exhaust valve is much lighter. Unserviced 500s seem to make 800-1000 hrs. 50-100% more than a 525

True. okay……
i’ll stand by 525efi’s being run at a little higher rpm then. Did some quick digging on oso and saw both 500efi and 525 efi use weak psi springs. Maybe 525’s running into soring fuss more. Seems likely. That’s my story and i’m sticking to it. :wink :lol

ICDEDPPL 04-04-2022 09:17 PM

33-36 baja is a great boat but man that engine compartment is tight .
Replacing sea pump impeller is like getting your teeth pulled with no novicane.

1MOSES1 04-04-2022 09:18 PM


Originally Posted by jeff32 (Post 4827756)
Broke a valve on my 500 efi close to 900 hours
the other 2 engines had 1100-1200 hours untouched and still ran fine, but rebuilt them anyways

Did you have bottom ends gone thru…if so what were the findings?

TomZ 04-04-2022 10:00 PM


Originally Posted by SB (Post 4827758)
True. okay……
i’ll stand by 525efi’s being run at a little higher rpm then. Did some quick digging on oso and saw both 500efi and 525 efi use weak psi springs. Maybe 525’s running into soring fuss more. Seems likely. That’s my story and i’m sticking to it. :wink :lol

"Planned maintenance" by Mercury? I've never understood why they run weak-ish valve springs when clearly better examples were available. Skip the interval, drop a valve, and a new engine is sold??


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