The Poppet Valve Rebuild Kit, replacing the Mercury 803062T1, is a vital maintenance component designed for a wide range of Mercury Marine and Mariner 135 HP to 200 HP V6 outboard engines, including models with 2.0L, 2.4L, and 2.5L displacement.
These stock outboards rely on the poppet (pressure relief) valve to manage water flow at mid-to-high RPMs, ensuring the cooling system maintains optimal operating temperature and prevents overheating.
Over time, the diaphragm, spring, and seals can degrade due to exposure to heat, pressure, and debris, resulting in erratic water pressure, high temperatures, and performance issues. This rebuild kit restores factory-spec function to the valve assembly and is compatible with numerous well-known Mercury V6 models such as the XR4, XR6, Magnum II, Magnum III, V135, V150, V175, and V200.
The kit includes a poppet valve, valve carrier, diaphragm, grommet, spring, screw, washer, and gaskets — all manufactured to meet or exceed OEM specifications. These parts are direct replacements for the original 803062T1 components and are suitable for two-stroke outboards commonly used in bass boats, offshore fishing boats, and recreational craft.
This kit fits across Mercury and Mariner V6 engines from 135 HP, 150 HP, 175 HP, to 200 HP, including the 2.0-liter, 2.4-liter, and 2.5-liter platforms used widely in both fresh and saltwater environments.
Installation is straightforward for most marine technicians and experienced DIYers, requiring basic tools and adherence to Mercury's service procedures.
Proper installation includes aligning the diaphragm and spring correctly, torquing fasteners to spec, and checking for leaks or misalignment. Post-installation testing should include monitoring water pressure and engine temperature under load to verify cooling performance.
Routine maintenance of the poppet valve system — along with thermostat inspection and periodic cooling system flushing — helps prolong engine life and ensures consistent power output. Whether you’re restoring performance to an older outboard or performing preventive service, the 803062T1 rebuild kit is essential for maintaining the health of your Mercury V6 engine.
For more information, contact Mike Hill at 714-697-1716 or email mike@buckshotracing77.com