Mercruiser 496MAG / 496MAG HO Marine Performance Parts
Running an inboard 496cid / 8.1L engine in your yacht or powerboat? Raylar’s marine performance packages are bolt-on replacement parts for any Mercruiser 496 MAG / 496 MAG HO, Volvo Penta 8.1Gi / 8.1GXi, Crusader Captain’s Choice 8.1 MPI / 8.1 HO MPI, Levitator 496cid or Marine Power 8.1. We’ve developed our marine performance kits to raise the level of performance, reliability and efficiency available from these engines.
Our products are direct bolt-on replacements for any of these marine applications.
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Marine Performance Parts
Our stage 1 marine performance package bumps the 496 / 8.1L to 540 horsepower & 600 ft-lbs of torque.
- BigPower Aluminum Cylinder Heads
- BP-203 Street / Strip Camshaft
- GEN7R Aluminum Intake Manifold
- 90MM Marine Cable Throttle Body
- 1.7 Ratio SS Roller Rockers & AFN nuts
- ARP Re-torqueable High Strength Head Bolt Kit
- Cometic MLS Head Gasket Set
Our stage 2 marine performance package bumps the 496 / 8.1L to 605 horsepower & 635 ft-lbs of torque.
- BigPower Aluminum Cylinder Heads
- BP-206 Max Effort High-Lift Camshaft
- GEN7R Aluminum Intake Manifold
- 90MM Marine Cable Throttle Body
- 1.7 Ratio SS Roller Rockers & AFN nuts
- BigPower Forged Flycut Pistons, Rings & Wristpins
- BigPower Forged I-beam Connecting Rods
- ARP Re-torqueable High Strength Head Bolt Kit
- Cometic MLS Head Gasket Set
Raylar 511 CID Stroker Performance Kits
Want even more power? Our 4.5" stroke crankshaft, forged I-beam connecting rods and forged pistons replace your exisiting rotating assembly adding cubic inches and more power. Direct replacement parts for your stock rotating assembly.
- (511cid stock bore / 518cid 0.030 over)
- 4.5inch Stroke Forged Crankshaft
- Forged I-beam Connecting Rods
- Forged Flycut Pistons
- Rings & Wristpins
Our popular 600HO kit, stroked to 511cid thanks to a 4.5 inch stroke crankshaft. Our 511 marine performance package makes 625 horsepower & 660 ft-lbs of torque.
- BigPower Aluminum Cylinder Heads
- BP-206 Max Effort High-Lift Camshaft
- GEN7R Aluminum Intake Manifold
- 90MM Marine Cable Throttle Body
- 1.7 Ratio SS Roller Rockers & AFN nuts
- ARP Re-torqueable High Strength Head Bolt Kit
- Cometic MLS Head Gasket Set
- 4.5inch Stroke Forged Crankshaft
- Forged I-beam Connecting Rods
- Forged Flycut Pistons
- Rings & Wristpins
Supercharged Marine Performance Parts
Please note: Our engine kits do not include superchargers.
Running boost on your 496cid engine? The stock hypereutectic pistons are not built to handle the high boost levels associated with many supercharger kits. We routinely see engines with cracked, chipped and even shattered pistons which resulting in catastrophic engine damage. Our stage 2 kits come with fully forged components, ensuring maximum reliability and performance in supercharged marine applications.
Our stage 1 marine supercharger performance package bumps the 496 / 8.1L to 650 horsepower & 675 ft-lbs of torque.
- BigPower Aluminum Cylinder Heads
- BP-111S Supercharger Camshaft
- 1.7 Ratio SS Roller Rockers & AFN nuts
- ARP Re-torqueable High Strength Head Bolt Kit
- Cometic MLS Head Gasket Set
- *Supercharger not included in kit.
Our stage 2 marine supercharger performance package bumps the 496 / 8.1L to 804 horsepower & 824 ft-lbs of torque.
- BigPower Aluminum Cylinder Heads
- BP-207S Supercharger High-Lift Camshaft
- 1.7 Ratio SS Roller Rockers & AFN nuts
- BigPower Forged Flycut Pistons, Rings & Wristpins
- BigPower Forged I-beam Connecting Rods
- ARP Re-torqueable High Strength Head Bolt Kit
- Cometic MLS Head Gasket Set
- *Supercharger not included in kit.
Keeping Stock Iron Cylinder Heads?
The stock iron cylinder heads respond very well to our 496 Roller Rocker & Camshaft Swap Kit, and modified intake manifold.
Raylar's full-roller camshaft kit for iron cylinder heads reuses stock head studs and fits under the stock valve covers. Includes the BP-203 camshaft and 1.70 ratio stainless steel roller rockers.
- Kit Includes:
- BP-203 Stage 1 Marine Camshaft
- 1.70 Ratio Stainless Steel Roller Rockers
Full Throttle Marine dyno tests a series of header options on a 496MAG HO. After installing our 525HO / 496cid Stage 1 marine kit they made 553 horsepower @ 5400RPM!
Header Shootout / Raylar 525HOWant Even More Power?
- > GEN7R Intake Manifold
- > 540cid Crate Engine Kit
- > CMI Sport Tube Long Tube Headers
- > Performance Marine Spark Plug Wires
Need A Tune?
We don't offer computer tuning, but we've met lots of good people who do. Check out our tuner list to find a tuner in your area.
496 MAG Computer Tuning496MAG Stage 1 MAKES 550+HP
Full Throttle Marine dyno tests a series of header options on a 496MAG HO. After installing our 525HO / 496cid Stage 1 marine kit they made 553 horsepower @ 5400RPM!
Raylar 525HO Makes 550+HP!Raylar Marine Stage 1
Raylar Marine Stage 2
GEN7R Intake Manifold
The stock intake manifold can’t meet the air flow demands of your Mercruiser engine in performance applications. Our GEN7R intake manifold has been engineered for one purpose, maximum airflow and power output in marine applications. Our GEN7R intake manifold incorporates shorter length, high velocity, tuned runners to produce stronger mid-range torque and higher RPM horse power with a large, unrestricted plenum to satisfy this engine’s demand for more air at higher RPM’s.
- 90MM / 102MM (4 bolt / LS2 style)
How Much Air Do Raylar Heads Flow?
Raylar Big Power cylinder heads out flow every 496 / 8.1L cylinder head on the market. Our combustion chambers promote a more even burn, increasing engine efficiency, fuel mileage, improving driveability and reducing detonation in forced induction applications. Check out the flow numbers for our standard Raylar CNC heads and our special-order CNC Extreme cylinder heads using the link below.
Cylinder Head Flow ComparisonMercruiser 496cid Cast Pistons Break
The stock 496 / 8.1L cast pistons are not designed to withstand the forces of extreme endurance use. We routinely see engines with cracked, chipped and even shattered pistons which result in catastrophic engine damage.
"Header-Proof" Ceramic Spark Plugs
Ceramic Spark Plug Wires - $350
8.1L engines with short and long tube headers routinely melt stock plug wires and even performance spark plug boots. Ceramic spark plug wires eliminate burnt spark plug boots in boats, trucks, hot rods and RVs. If you've had this problem before or don't want to worry about it in the future, check out our 45 degree ceramic plug boots which are rated to withstand extreme temperatures up to 2000°F!
Ceramic Spark Plug Wires