Just bought a cute (OLD) 1976 AMF Crestliner Boat - Model Muskie M550 and it has the 1982 Mercury 50 HP that hasn't been run for 5 years. All your excellent instructions will be helping me a whole lot! It already has by telling me how to take the covers off! LOL THAT right there was a great start. I think I owe you lunch & a beer, Bud!
Recently bought a boat with a 1982 50 hp 2 stroke the process is almost the same I was able to guess the rest but your a life saver thanks for you video not to many videos on these older Mercury’s
@@TheAfterWorkGarage adding some personal touches and fixing a few soft spots in the floor but after watching your video yesterday I was able to fix my water pump and now the motor is lake ready couldn’t be more grateful
Man I'm so glad I found your video somehow. I have a newer 40hp mercury (I thought it was a 95), and when I enter the serial number online it gave me all the wrong part numbers. Yours looks exactly like mine. Nice to see an example of how one is setup. My impeller had a little chip out of one of the vanes, hoping it doesn't cause me any issues wherever it went.
I picked up an old 402 40hp merc in August 2020. Never touched an outboard motor before but basically did what you've done, taken it all apart etc. Kinda scary but if you don't try you don't learn. An old rubber impeller at some point had broken down and parts had got stuck inside the engine. Lack of water in the pee tail. Went to remove the manifold cover I think it's called, three bolts snapped off. However to access all these bolts you had to also remove the engine from the outer casing/cover. Wasn't sure I'd be able to get it all back together at this point. Found many pieces of the broken impeller with the cover removed. Had to drill out the three snapped bolts and retap one of them and replace it with a larger bolt. Got it all back together and running, the pee tail thing doesn't shoot as much water as it should so there must be still small parts blocking the flow. The one thing I need help/advice with is the two adjustment screws related to the throttle and firing. Any idea how to tune or adjust there? The engine runs ok, but I had to remove the two bolts and now I'm not sure how to adjust them the right way.
thats hands down one of the best videos to ever be placed on this crazy internet. for the first time someone had no other agenda than to hopefully figure it out. like old washing machines that motor ell last a lifetime i just cant believe how much bullshit is involved . like didnt one of the engineers for mercury say " wait a minute , why arent we blocking access to everything" .... either way good work i hope part two you take apart someones hot air balloon
I have a 35hp same early 80s that looks the same inside. I have 95psi for compression in both cylinders. Might have been a little higher if I would have gave it some more turns. Thanks for the video! It helps a lot with mine
Thanks for the feedback, it definitely took a little bit to figure out what parts I needed. I'm hoping I don't have too much of a delay on the kits I ordered.
awesome video , restoring same engine in a 35 horse power . still looking for a wiring diag . this forty is identical in everything i see so far . looking forward to watching next vid . leg was off mine when i bought it and didnt realize that cam lock for reversing was what that piece was so learning from you already cheers matey
@@m4chschnell Mine also has striped and colored wires. There are a number of wiring color codes online that might be helpful. One site I have seen is below: www.electricaltechnology.org/2020/07/marine-boat-cable-wire-color-codes.html
I have a 1982 40hp mercury thunderbolt. There is a rod that goes into the lower part of the motor. It engages the lock that holds the motor in reverse. Can you do a video on that?
My water pump impeller in my 1994 40 hp also is hard to get on/off. It’s a pressed fit from what I can tell. Once I had to use breaker bars to get one off. You may also have to lightly sand the drive shaft to get the new one on as any small irregularly will cause it to hang up.
Thanks for your report. I also had trouble getting the impeller on, and ended up doing a little sanding on the drive shaft as well (I will be uploading that in Part 2 as soon as I get a shot of it running on a boat). On mine, it looks like there was a bit of a flare on the driveshaft just above where the impeller sits which I had to sand down. I also took a 19m wrench to straddle the driveshaft so I could use a mallet to work the the impeller down onto the key.
What you experienced is typical when working on older Mercury motors. Hopefully she'll treat you right. There is a reason you don't see a lot of them still around like the do OMC stuff.
Thanks for the Video, I have an Operation and Maintenance Manual for the Mercury Outboard Models 40,50 and 70 HP it is not a motor manual it's just the owners manual if you want I will scan it and send it to you as a PDF. I just got my dad's 1982 lowe 16' bass boat. that has been sitting in a field for about 15 years.
Good luck with the bass boat, that's very exciting, and a lot of fun to bring something back to life. Hopefully you have, or can find a motor for it as well. Lowe's are great boats.
I'm not sure if you found a place for parts this is the site I found, I like them because they have a blown-up schematic and not just the part name. www.marineengine.com/
@Samir Fernandes, finally got around to scanning that Manual into a pdf, 9 months later but some things you just can't rush... , I'm not sure how to get it to you since youtube won't let me attach a file.
How did you get the fuel filter housing off? Does it just turn? Or do I need to loosen the screw on top? It's pretty tight and I don't want to crack it. I have same exact engine.
I’ve got the same motor, my magnets on the inside of the flywheel have come off and the serial number is worn down. Been trying to find a part number for the flywheel and can’t find it. Any chance you have the part number for that flywheel?
Yeah the impeller and impeller housing that I change out in the latter half of this video is the water pump. If you're talking about the fuel pump, I have actually changed this out as well, but have been waiting to get a video together on it until I can get the block back together and on the motor. I just moved to a different city from my shop, so I'm looking at ways to get my shop moved down to Dallas so I can keep things going! Best of luck with your motor!
I got the exact same engine and year yesterday and an old boat project. I was wondering how do you know if it's four stroke or two stroke it only seems to have one red gas can inside the boat hooked to the engine...???
If it's the same engine - or pretty much any older outboard - it's a 2-stroke. It only has one gas can because older 2 strokes required you to mix the oil and gas in the tank rather than having a separate oil reservoir. You can also tell since there is no engine oil in the engine, and no timing chain or camshaft. Hope this helps!
Sir, thank you so much for your videos! I have the same motor! do you mind telling me where the switch box gets connected? There is a little black cable sticking out in the back but I don't know where it goes. Any help would be greatly appreciated. Thanks
I have same motor. I would like to know which way to turn the choke lever at front of motor. Which way is open and which way is closed? Motor is on boat and I dont wana take it off. Can't really see carb very well
I wish I had a good answer for this - Planning a trip to back to Kansas City later this month just to try to finish up this motor, hopefully can get it done and filmed then. I feel bad it's been so long!
i have this exact same motor, and it runs fine, but is pretty unreliable when it comes to starting the engine, and it tends to die at random times on the water. my brother says the carburetor needs cleaning, is that it?
If you haven't done anything with the carb, I'd definitely start there. I would also check the fuel pump and filter just to make sure you're getting good fuel flow. I found that this motor had bad reed valves, which was causing starting issues for me. Unfortunately that's not the easiest fix on this particular outboard, but it is something to consider. Good luck, and if you figure it out, I'd love to hear what the issue was.
I have this exact same motor.. so I broke the plunger assembly that goes up in the solenoid for electric choke... that part is now obsolete and thier are no after markets I see .. will this be a problem
You're likely going to have to look around online a bit. Definitely try to get the part number on the starter motor, and make sure you match it. If you get really desperate, starter motors can be rebuilt - but that would take skills that I certainly don't have.
@@TheAfterWorkGarage my motor was born without the teeth on the flywheel and also without starter motor 😣🤕 In addition it's very hard to start with hands. I'm doing it only because I'm a vintage motors lover and I'm poor so I can't afford a new one. 🤣🤣 Have a nice day ;)
Hey, love your channel and love your videos. Last season i found that my engine was popping up in reverse and not locking down. After watching your video I realized that the previous owner must have put in the reverse locking mechanism in wrong. I took the lower unit off to fix it, but when i took it off there were no seals for the top of the drive shaft or the seal that goes over the copper pipe for the water cooling system. Do you think this is a big issue? I've never had a problem with the engine, it has worked great!
I'm glad it was helpful! I honestly don't completely get the spline seal thing, since the lower crankcase seal is completely separate. I think they may just be there to keep the grease on the splines from drying up or being washed away. This is just a total guess though. I am not a Mercury expert, and there are many people who know far better than me. If your motor is running fine, I'd say it's probably not a big issue.
This is a good question. I've usually just tried googling the part ID's if I can find them on the original, and doing my best to match them up by eye. I've gotten lucky so far, though I did initially order the incorrect carb kit. Sorry I don't have a one stop shop source to share, but with these old motors, sometimes it's a challenge. Perhaps someone else knows better than I and can help us out!
I'm honestly not sure where to readily get parts other than to suggest a google search. I would also just recommend that you make sure it's the stator that's bad as well, so you're not buying a part you don't need.
The big question I'd have to ask is what caused the bent crank, did it hit something? Fortunately if you can find a crank in good condition, replacing it isn't as bad as on a 4 stroke. The case just splits apart and you can pop another one in.
@@TheAfterWorkGarage the flywheel nut wasn’t the original and it was loose and over time cause the bend. So I can easily replace crank with the whole motor still together
I have an 1983 35 horse Mercury. When I start it it dies after a second. If I give it some throttle it will idle as long as I want it too. Do I need to adjust the idle position, if so how would I do that? Or is it something else?
Hi! That sort of depends. If the idle is set really low, you can try adjusting it up, however if it seems like you have to rev it up higher than a normal idle (sorry I don't know the actual normal idle for this motor), then you have some other problem going on. That's actually a similar symptom to what I had going on with this motor that ended up being worn out reed valves. However, this can also be a symptom of low compression, or a poorly adjusted carb. Basically I'd start with the easy things (clean the carb, check compression) to rule things out, and then move on to the other possible issues. Good luck, and I'd love to hear what the issue is if you get it figured out!
Hmm, that sounds like it's a carb cleaning/adjustment issue. The only thing between the bowl and the carb body is the jets and the venturi. I'd definitely start with a carb cleaning/rebuild kit, and see if that resolves the issue.
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Just bought a cute (OLD) 1976 AMF Crestliner Boat - Model Muskie M550 and it has the 1982 Mercury 50 HP that hasn't been run for 5 years.
All your excellent instructions will be helping me a whole lot! It already has by telling me how to take the covers off! LOL THAT right there was a great start.
I think I owe you lunch & a beer, Bud!
Recently bought a boat with a 1982 50 hp 2 stroke the process is almost the same I was able to guess the rest but your a life saver thanks for you video not to many videos on these older Mercury’s
Awesome, I'm glad it was helpful. Are restoring the boat as well?
@@TheAfterWorkGarage adding some personal touches and fixing a few soft spots in the floor but after watching your video yesterday I was able to fix my water pump and now the motor is lake ready couldn’t be more grateful
@@richardwhite9387 That's great to hear. Fixing up a boat the way you like it can be very rewarding. Have fun with it!
Man I'm so glad I found your video somehow. I have a newer 40hp mercury (I thought it was a 95), and when I enter the serial number online it gave me all the wrong part numbers. Yours looks exactly like mine. Nice to see an example of how one is setup. My impeller had a little chip out of one of the vanes, hoping it doesn't cause me any issues wherever it went.
I picked up an old 402 40hp merc in August 2020. Never touched an outboard motor before but basically did what you've done, taken it all apart etc. Kinda scary but if you don't try you don't learn.
An old rubber impeller at some point had broken down and parts had got stuck inside the engine. Lack of water in the pee tail.
Went to remove the manifold cover I think it's called, three bolts snapped off. However to access all these bolts you had to also remove the engine from the outer casing/cover.
Wasn't sure I'd be able to get it all back together at this point.
Found many pieces of the broken impeller with the cover removed.
Had to drill out the three snapped bolts and retap one of them and replace it with a larger bolt.
Got it all back together and running, the pee tail thing doesn't shoot as much water as it should so there must be still small parts blocking the flow.
The one thing I need help/advice with is the two adjustment screws related to the throttle and firing. Any idea how to tune or adjust there?
The engine runs ok, but I had to remove the two bolts and now I'm not sure how to adjust them the right way.
thats hands down one of the best videos to ever be placed on this crazy internet. for the first time someone had no other agenda than to hopefully figure it out. like old washing machines that motor ell last a lifetime i just cant believe how much bullshit is involved . like didnt one of the engineers for mercury say " wait a minute , why arent we blocking access to everything" .... either way good work i hope part two you take apart someones hot air balloon
Thank you so much! (no hot air balloons so far lol)
I have a 35hp same early 80s that looks the same inside. I have 95psi for compression in both cylinders. Might have been a little higher if I would have gave it some more turns. Thanks for the video! It helps a lot with mine
I'm glad it was helpful. Hope your getting to enjoy your motor on the water!
nice vid! cant wait for the final product of it! regular quicksilver controls will work fine
Thanks! I'm looking forward to it too!
I’ve been waiting for more parts on these engines! Thanks for sharing. Any quicksilver controls shall work
Thanks for the feedback, it definitely took a little bit to figure out what parts I needed. I'm hoping I don't have too much of a delay on the kits I ordered.
Always enjoy your video, bro! Thanks for posting
Thank you!
awesome video , restoring same engine in a 35 horse power . still looking for a wiring diag . this forty is identical in everything i see so far . looking forward to watching next vid . leg was off mine when i bought it and didnt realize that cam lock for reversing was what that piece was so learning from you already cheers matey
Awesome, thanks for the comment! If I come across a wiring diagram online I'll point you to it.
@@TheAfterWorkGarage yeah every diagram I see has plain coloured wiring mine has coloured strips . Still looking . Cheers
@@m4chschnell Mine also has striped and colored wires. There are a number of wiring color codes online that might be helpful. One site I have seen is below: www.electricaltechnology.org/2020/07/marine-boat-cable-wire-color-codes.html
Order a manual.
Whats the model number on your 35hp?
I have a 1982 40hp mercury thunderbolt. There is a rod that goes into the lower part of the motor. It engages the lock that holds the motor in reverse. Can you do a video on that?
Where is the release for that reverse lock😊
Plz
Mines stuck in reverse
My water pump impeller in my 1994 40 hp also is hard to get on/off. It’s a pressed fit from what I can tell. Once I had to use breaker bars to get one off. You may also have to lightly sand the drive shaft to get the new one on as any small irregularly will cause it to hang up.
Thanks for your report. I also had trouble getting the impeller on, and ended up doing a little sanding on the drive shaft as well (I will be uploading that in Part 2 as soon as I get a shot of it running on a boat). On mine, it looks like there was a bit of a flare on the driveshaft just above where the impeller sits which I had to sand down. I also took a 19m wrench to straddle the driveshaft so I could use a mallet to work the the impeller down onto the key.
What you experienced is typical when working on older Mercury motors. Hopefully she'll treat you right. There is a reason you don't see a lot of them still around like the do OMC stuff.
Thank you, that's good to hear. Hopefully it won't have too many surprises.
Great video
Glad you liked it!
I have the exact same one but when trying to remove the lower unit it is stuck and won't come off its opened up a little but is stuck. Any ideas?
If you're sure you have everything disconnected, it could be a stuck driveshaft. Sometimes the splines get really seized together.
Thanks for the Video, I have an Operation and Maintenance Manual for the Mercury Outboard Models 40,50 and 70 HP it is not a motor manual it's just the owners manual if you want I will scan it and send it to you as a PDF. I just got my dad's 1982 lowe 16' bass boat. that has been sitting in a field for about 15 years.
Good luck with the bass boat, that's very exciting, and a lot of fun to bring something back to life. Hopefully you have, or can find a motor for it as well. Lowe's are great boats.
I'm not sure if you found a place for parts this is the site I found, I like them because they have a blown-up schematic and not just the part name. www.marineengine.com/
Hi! Would you mind sharing this manual with me? I'd appreciate it! thanks
@@samir_wf as soon as I scan it I will make it available. Keep in mind this just an owners manual.
@Samir Fernandes, finally got around to scanning that Manual into a pdf, 9 months later but some things you just can't rush... , I'm not sure how to get it to you since youtube won't let me attach a file.
Do you have a video for this motor for setting timing
How did you get the fuel filter housing off? Does it just turn? Or do I need to loosen the screw on top? It's pretty tight and I don't want to crack it. I have same exact engine.
Do you happen to have the part numbers for the impellar and carb rebuild kit?
I’ve got the same motor, my magnets on the inside of the flywheel have come off and the serial number is worn down. Been trying to find a part number for the flywheel and can’t find it. Any chance you have the part number for that flywheel?
Let me get back to you. Next time I'm at my shop I'll take a look!
Mine wont go in neutral by pulling on that shifter inside. Whats going on on??
I have the same motor but a 1979 model. Need to change or rebuild the waterpump. Have you done yours?
Yeah the impeller and impeller housing that I change out in the latter half of this video is the water pump. If you're talking about the fuel pump, I have actually changed this out as well, but have been waiting to get a video together on it until I can get the block back together and on the motor. I just moved to a different city from my shop, so I'm looking at ways to get my shop moved down to Dallas so I can keep things going! Best of luck with your motor!
I got the exact same engine and year yesterday and an old boat project. I was wondering how do you know if it's four stroke or two stroke it only seems to have one red gas can inside the boat hooked to the engine...???
If it's the same engine - or pretty much any older outboard - it's a 2-stroke. It only has one gas can because older 2 strokes required you to mix the oil and gas in the tank rather than having a separate oil reservoir. You can also tell since there is no engine oil in the engine, and no timing chain or camshaft. Hope this helps!
Sir, thank you so much for your videos! I have the same motor! do you mind telling me where the switch box gets connected? There is a little black cable sticking out in the back but I don't know where it goes. Any help would be greatly appreciated. Thanks
I have same motor. I would like to know which way to turn the choke lever at front of motor. Which way is open and which way is closed? Motor is on boat and I dont wana take it off. Can't really see carb very well
When are you going to release part 4 of the 1982 Mercury 40hp
I wish I had a good answer for this - Planning a trip to back to Kansas City later this month just to try to finish up this motor, hopefully can get it done and filmed then. I feel bad it's been so long!
Can you put the link to the carb kit you used?
i have this exact same motor, and it runs fine, but is pretty unreliable when it comes to starting the engine, and it tends to die at random times on the water. my brother says the carburetor needs cleaning, is that it?
If you haven't done anything with the carb, I'd definitely start there. I would also check the fuel pump and filter just to make sure you're getting good fuel flow. I found that this motor had bad reed valves, which was causing starting issues for me. Unfortunately that's not the easiest fix on this particular outboard, but it is something to consider. Good luck, and if you figure it out, I'd love to hear what the issue was.
Hello, dear sir, can you tell me the starter number, how to order...? Thank you.
I have this exact same motor.. so I broke the plunger assembly that goes up in the solenoid for electric choke... that part is now obsolete and thier are no after markets I see .. will this be a problem
I have the exact same motor and need to replace the carb. Any clue where I can find one?
Ebay
throttle cable ? how do i connect it. sorry for bad english
where can i find engine gaskets.
We have 1979 40
I had same arc with cracked plug
Hi, I'm from Italy and I have the same motor of yours. I have a problem with the starter... Do you know where can I buy parts?? Thank you
You're likely going to have to look around online a bit. Definitely try to get the part number on the starter motor, and make sure you match it. If you get really desperate, starter motors can be rebuilt - but that would take skills that I certainly don't have.
@@TheAfterWorkGarage my motor was born without the teeth on the flywheel and also without starter motor 😣🤕
In addition it's very hard to start with hands.
I'm doing it only because I'm a vintage motors lover and I'm poor so I can't afford a new one. 🤣🤣
Have a nice day ;)
do you know anything abt the mercury 402 40hp from 1972?
Hey, love your channel and love your videos. Last season i found that my engine was popping up in reverse and not locking down. After watching your video I realized that the previous owner must have put in the reverse locking mechanism in wrong. I took the lower unit off to fix it, but when i took it off there were no seals for the top of the drive shaft or the seal that goes over the copper pipe for the water cooling system. Do you think this is a big issue? I've never had a problem with the engine, it has worked great!
I'm glad it was helpful! I honestly don't completely get the spline seal thing, since the lower crankcase seal is completely separate. I think they may just be there to keep the grease on the splines from drying up or being washed away. This is just a total guess though. I am not a Mercury expert, and there are many people who know far better than me. If your motor is running fine, I'd say it's probably not a big issue.
where can i find the complete wiring diagram
One question: Does this engine use mix gasoline or regular gasoline
There’s a little arm that works the butterfly valve on the back bottom that also connects to the c under the carb could you show this
Where are you finding parts for this engine
This is a good question. I've usually just tried googling the part ID's if I can find them on the original, and doing my best to match them up by eye. I've gotten lucky so far, though I did initially order the incorrect carb kit. Sorry I don't have a one stop shop source to share, but with these old motors, sometimes it's a challenge. Perhaps someone else knows better than I and can help us out!
yea that carb bolt was apain for me too lol
I kept thinking there must be a trick to it, but if there is, I don't know it.
use a ratchet strap on lower units to hold them when taking off and putting back on
i have an 40hp 1983.....with no sparks....cant find the stator....or compatible stator
I'm honestly not sure where to readily get parts other than to suggest a google search. I would also just recommend that you make sure it's the stator that's bad as well, so you're not buying a part you don't need.
What's the RPM'S at idle supposed to be??
Why would my coils be arching on 40 horse mercury 2 stroke
Dude I’ve got a 83 fully rebuilt but crank is bent has controls.
40hp
The big question I'd have to ask is what caused the bent crank, did it hit something? Fortunately if you can find a crank in good condition, replacing it isn't as bad as on a 4 stroke. The case just splits apart and you can pop another one in.
@@TheAfterWorkGarage the flywheel nut wasn’t the original and it was loose and over time cause the bend. So I can easily replace crank with the whole motor still together
Is it auto mixing petrol and oil
No, this is before that technology was common. You still have to add the oil to the gas tank.
Does anyone know the type of oil this motor uses?
This motor uses regular 2-stroke oil pre-mixed with gas at 1:25 to 1:50 ratio. I'd recommend somewhere around 1:30.
@@TheAfterWorkGarage just one more question where did you get the impeller kit and how much did it cost ?
I NEED THE GREY FLYWHEEL , CAN YOU HELP ?
Do you have a red flywheel currently?
@@greauxpete No , it's grey like yours and impossible to find , 2 magnets ..
I have an 1983 35 horse Mercury. When I start it it dies after a second. If I give it some throttle it will idle as long as I want it too. Do I need to adjust the idle position, if so how would I do that? Or is it something else?
Hi! That sort of depends. If the idle is set really low, you can try adjusting it up, however if it seems like you have to rev it up higher than a normal idle (sorry I don't know the actual normal idle for this motor), then you have some other problem going on. That's actually a similar symptom to what I had going on with this motor that ended up being worn out reed valves. However, this can also be a symptom of low compression, or a poorly adjusted carb. Basically I'd start with the easy things (clean the carb, check compression) to rule things out, and then move on to the other possible issues. Good luck, and I'd love to hear what the issue is if you get it figured out!
Should ground those plugs....before you blow the switch box.... inexperience will get you one day
Im getting gas to carb bowl but am not getting it to cylinder
Hmm, that sounds like it's a carb cleaning/adjustment issue. The only thing between the bowl and the carb body is the jets and the venturi. I'd definitely start with a carb cleaning/rebuild kit, and see if that resolves the issue.
Hey
Wat a pain in the ass motor to work on.ill stilk to japanese
It just has "character" lol. No it's a pain.