Mercury Thunderbolt 500

Bulkkis

Recruit
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Jun 13, 2013
Messages
4
Hi!
First of all sorry for my bad english :)
Can anyone help me with mercury thunderbolt 500 controls change?
I have two engines, one is from 80:s (broken) and the second one is from 1972. Both are thunderbolt 500, but there is some difference in those. So can i mount the 1972 engine on the boat with controls for the newer engine? I was about to leave the steereng wheel and the throttle on the boat, but i need some instructions and some pictures to mout the controls properly on my older engine.
Please help me with this problem :)
Thank you.
 

Yesterday

Petty Officer 1st Class
Joined
Feb 21, 2012
Messages
354
Re: Mercury Thunderbolt 500

Do you still have the controls for the newer motor?
 

Bulkkis

Recruit
Joined
Jun 13, 2013
Messages
4
Re: Mercury Thunderbolt 500

Yes i do. And i have to bolt the older motor on a boat with newer controls.
 

Yesterday

Petty Officer 1st Class
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Feb 21, 2012
Messages
354
Re: Mercury Thunderbolt 500

Yes i do. And i have to bolt the older motor on a boat with newer controls.
OK well the only issue "may" be the wiring. The throttle & transmission controls should still be the same. since you have the connector if you need to adapt the wiring it's easily doable. There are only 6 or 7 wires and so adapting them should be easy, all you will need are both wiring diagrams. I'm quite sure I should have one for the 72 500. If you can provide a serial number for the newer one you intend to use the controls from, I can draft you up a diagram to convert them, again if it's even necessary.
 

Bulkkis

Recruit
Joined
Jun 13, 2013
Messages
4
Re: Mercury Thunderbolt 500

Hi!
The serialnumber from newer engine is 9362611 and number for engine i will use is: 9021072.
Can you help me please with other problem: how can i change the rack from other motor to other? Do you have any pictures on how mahy bolts i have to remove?
Thank you for your help.
With best regards: Antti Husu from Finland :)
 

Yesterday

Petty Officer 1st Class
Joined
Feb 21, 2012
Messages
354
Re: Mercury Thunderbolt 500

I dont have pics but I can tell you that you remove:
Fro the top section:
1) Power head
2) Cowling
2) Exhaust extension plate

Bottom:
2 bolts and possibly two caps. Very straight forward this part.


I will work on the wiring in the next day or two.

<Edit>
I was looking and it seems I do have some pictures, but from a larger motor:
exhaust extension removed.jpgleg separated.jpgpwr head cowling removed.jpg


So as you can see once the power head, cowling & exhaust extension plate are off it's just the removal of four nuts.
here is your motor's parts breakdown: (the 1972)
http://www.crowleymarine.com/mercury-outboard/449.cfm

For your other, though I'm still trying to find the year:
http://www.ishopmarine.com/ishop/js...&isForSupStore=false&cCatFilter=&eCatSupFldr=

Service manuals found here:
http://boatinfo.no/lib/mercury/manuals/

Wiring diagram for the 1972:
http://www.maxrules.com/oldmercs/Wiring/1966ona/26A.jpg

Now the hard part:
According to this:
http://www.storesonline.com/site/573683/page/609764
Your donor motor seems to be a 1980/81, but it seems vague. I'm still trying to find something more specific or clear, but it's not an easy find.
 

Yesterday

Petty Officer 1st Class
Joined
Feb 21, 2012
Messages
354
Re: Mercury Thunderbolt 500

Well sir, after investing about 1.5 hours of searching, I simply can't find the year of the 9362611 for sure.
Not expert advise!!:
If they were my motors, I would plug it in and try it. :)
 

carholme

Rear Admiral
Joined
Sep 4, 2010
Messages
4,845
Re: Mercury Thunderbolt 500

Your s/ns are both for made in Belgium engines.

9021072: 50 500 4-cyl 9006164 9047653 1973 Belgium

9362611: 50 50 Classic 4-cyl 9248006 9420790 1979 Belgium

No Belgium made 50 hp 2s were built between '80 and '84.

You can see that on this link:

us-europe - Download - 4shared

Gerry
 
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