68 Merc 200

[Arkman]

I dont know too much about this thing but it doesn't have any spark plugs in it. I'm not sure what the gap is when I put new plugs in it. Does anyone know?

 

[7920hpMercury]

Re: 79 Merc 200

Re: 79 Merc 200

Nice motor and looks to be in great condition. Decals look great.

I would guess that you have a 1968 basis decals and tiller handle. Check the first post here for a serial number year to verify. serial number should be in between the transom clamps and on the motor block.

Spark plugs should be Champion L4J with .030gap. Also suggest you get a Mercury service manual and/or Seloc manual which is full of good info to operate and maintain.

Good luck!

 

[Arkman]

Re: 79 Merc 200

Re: 79 Merc 200

Hey thanks for the info. I was told one time that it was a 79 but hey what do I know. It sat in storage for like 15 years so its been fairly well protected. It is in good condition. I've been looking for a service manual but I dont know what to get or where to get one. I'm replacing the spark plugs, changed the lower unit oil, and i'm going to try to clean out the carb as soon as I get a service manual.

Thanks again for the info, I'll take it off the boat and find the serial number and look it up.

 

[7920hpMercury]

Re: 79 Merc 200

Re: 79 Merc 200

I would suggest first verify the serial number as you say and then check ebay or Mercury direct to get the correct service manual.

I also like Seloc manuals.

Also a good idea to get a parts list direct from Mercury as it shows the exploded parts view and the correct numbered parts.

If in fact, this is a 68, I also suggest checking lower oil lube frequently as the original 68 had a carbon steel drive shaft which tend to rust. Grubbs makes a stainless sleeve to fix this or you can install a stainless drive shaft (I am pretty sure the later stainless drive shaft will fit).

 

[Arkman]

Re: 79 Merc 200

Re: 79 Merc 200

Thanks for the info. I've been looking for a serial number but I can't find one anywhere close to the transom mount. I've tried to find one on the engine block but I think all I am finding are part numbers. I've found a photo of someone else's 69 merc and it showed the number on the transom and mine doesn't have that. Any suggestions?

Josh

 

[7920hpMercury]

Re: 79 Merc 200

Re: 79 Merc 200

If a 68, should be 2296267 - 2550064, so a 7 digit number stamped on the block.

I think this vintage stamped the number on top of the block near rear where the water tattle tell hose exits the powerhead.

Also later stamped on the block on a boss starboard side near rear near top. And later stamped on the port side near front near top where cranks halfs split. I have also seen blocks very late or must be a replacement powerhead with no stamping. Should be an aluminum nametag on the tilt tube between the clamp handles, sounds like it is missing.

Good luck, hope this helps.

 

[Arkman]

Re: 79 Merc 200

Re: 79 Merc 200

FOUND IT!!! It was hiding but I got it. It is a 243 Number so it must be a 68. I just realized that I had the wrong plugs as well. But I never used them so now I will just set them aside and get the right ones. I'm going to try to clean out the carb too. So far I replaced the plugs...which I have to do again and changed the lower unit oil. The oil had a drip of water but wasn't discolored and no rusty looking water. Should I be concerned. It was a dark brown like other lower unit oil I've seen. And a very minimal amount of water. Any other things I should be looking out for.


Thanks again for all your help! I'm a lot farther then I was a week ago. I also picked up a manual for it. That will help a lot!
Josh

 

[7920hpMercury]

Re: 79 Merc 200

Re: 79 Merc 200

Sorry to say any water in the lower unit is not good.

You might run the motor in water and change the oil a couple of times to make sure you are actually getting water in the lower unit.

If you have to rebuild the lower unit, it is a reasonable job with the service manual. The main item needed is a cover nut tool, which you can make from a piece of pipe and cut slots or buy on ebay. Getting the cover nut off can be a challenge. Should have an off/on arrow on it plus use plenty of PB blaster and patience!

Good luck and lots of expertise here to help you out! Great motors!

 

[Arkman]

Re: 79 Merc 200

Re: 79 Merc 200

After doing some reading that was my plan. Run it a few times and change the oil a few times and see if there is water in it. Last time I wasn't very careful to make sure that the bucket I used was clean, so there could have been water in there too. Well see. I just took out the carb tonight and cleaned it. There was a little bit of gunk in the bottom of the fuel bowl that I couldn't get out, but I'm not sure if that is an issue or not. What do you think. It just looked like the metal was discolored not like there was actually a build up of stuff. I tried to take a picture but I couldn't get a good shot of that inside space.

 

[Arkman]

Fuel Leak

Fuel Leak

Well, I got everything cleaned up and the carb all clean and gaskets replaced. Put in new spark plugs and replaced my gas hose and gave it a pull!! and another, and another. Really I only had to pull about 10 times and it tried to go. One more good pull and it started. Ran for about a minute and died. Did that a few times and then I started looking around. Everytime it died the ball on the fuel line was soft, so I would squeeze it again and start it up. I noticed that one of the fuel lines going into my fuel pump(?) was leaking. When I would prime it fuel would squirt out right where the line goes into the brass fitting. See attached photo for the fitting in question. Is there a tool to just crimp that down or should I get a new fuel line? Is this the most likely reason my motor would die after about 30 sec to a min of running?

Thanks!!!

 

[7920hpMercury]

Re: 79 Merc 200

Re: 79 Merc 200

Good news, you got it running!

Fuel bowl gunk? if you scraped the gunk out and loose stuff and just aluminum is discolored, I would not worry about it. Make nothing is plugged up with carb cleaner.

That fitting looks like the original style Mercury hose connection to me. So, I would guess you maybe have some 40 yr old rubber hose there.

I would suggest you change this over to some common hardware by getting a couple of brass fittings (barbed brass hose fitting & an 1/8"(?) NPT ell?) and install a new fuel line using some new rubber fuel line hose.

I think you said you cleaned the carbs. If it does not run right after fixing the fuel hose, you might check and replace the fuel diaphram in the fuel pump.

Good luck!

 

[Arkman]

Re: 79 Merc 200

Re: 79 Merc 200

Hey thanks for the reply. I just was out doing some more looking and found a crack in the hose. So its got to go. I'm not sure where to find the more modern options for this. I found an original house from oldmerc.com but they are like 30 bucks each. Should i just take that hose off and bring it to a place like Napa and they can get me a new one? Any suggestions. I'm hoping that i can find a kit to do the diaphram on that bad boy too. Since I have it all apart, I might as well fix that too.

Some more maybe good news for me. When I was out looking at it I found a part I didn't know what it did. After some more inspection I think it is an electric start. I've been researching for the last hour but I cant find anything that says that year had electric start. I dont think its hooked up, the sprocket on top doesnt line up with the fly wheel, but I maybe able to get that hooked up and have myself and electric start. Any thoughts?

Thanks again for all your help!

 

[Arkman]

Re: 79 Merc 200

Re: 79 Merc 200

So I've been doing some more research on the electric start. I'm not totally certain on how this all works. Right now I can see that the sprocket on the starter and the sprocket on the flywheel do not line up. I'm assuming thats because its set up to be a rope start. I also don't understand how the motor gets hooked up to do this. I see on the side of the motor a connector that has a bunch of pins. I'm assuming there is something i plug into that. I would image that there is something that has an ignition switch of sorts and some battery connector.

I see the starter is connected to another object by a thick white wire. Which gets connected back to the previously mentioned plug on the side of the motor. Assuming that all the parts in the motor are working properly. All I would need is the wires that plug into the side maybe? Am I on track here? Any thoughts on what I would need and where to get it?
Thanks!

 

[Arkman]

Re: 68 Merc 200

Man, I've been struggling to find some replacement fuel lines. I've been to the local outboard shops and they look at me like i'm crazy. Went to NAPA and they said they couldn't make anything like that. I'm not sure where to find this stuff.

So I found this kind of stuff all over. http://www.fastfittings.com/hose-barb I'm just not sure that it will work for my application. What do you guys think?

 

[Arkman]

Re: 68 Merc 200

Well I made some fuel lines. It's a long story of a project but boy does that thing run now. Thanks for the feedback! And let me know if you know anything about the electric start!

Josh

 

[7920hpMercury]

Re: 68 Merc 200

Good news and glad to hear you got it running.

I do not know offhand about electric start. I suggest you get the Mercury service manual, 68 to 74 either from Mercury direct or ebay and/or get the Seloc manual for this year and they have many electrical diagrams on how to hook up the electric start. Since this motor is similar to a lot of this vintage, somebody could have set up electric start even though it may not have originally had electric start.

Good luck.

 

[Arkman]

Re: 68 Merc 200

Thanks again. I got a service manual but it doesn't really say too much about the electric start. From what I can tell I have all the innards for the electric start, I think I just need to figure out the wireharness for the exterior part, the thing that connects to the battery and ignition. Another mission for another day!

Thanks again!

 

[Arkman]

Re: 68 Merc 200

Hey, another question for you. I took it out of the test bucket and noticed a lot of oil in the water. So I got suspicious and decided to drain the lower unit oil again. WHITE!!! When taking the drain plug and the top plug out I noticed there is no gasket on the screws. Could enough water get in there to cause an issue? I'm assuming that I need to reseal the lower unit, which is fine, but if water could get in around the screw without a gasket I'd like to try that. You mentioned a sleeve that grub makes to cover that carbon steel part. Where would I find that?

Thanks!

 

[AMD Rules]

Re: 68 Merc 200

Try the gasket on the screws first. They will suck in a lot of water without a gasket.

 

[Arkman]

Re: 68 Merc 200

So I tried to replace the gaskets and that didnt work. Its still milky white. Is it ok to leave oil out of the lower unit for a couple of days? Or should I fill it back up until I get to fixing it?

Josh