1969 Merc 500e timing (contradicting how' to) I searched fyi, HELP

[nickoli1]

First off I did a large , multi phrased search using google and this forum for answers before I posted. I have read many different topics, which most dont relate to my motor. There have been many merc 500 threads but all of them refer to a flywheel with 1 timing mark as mine has 2, and other mecrs with 2 are all 100hp's. So there's that.

I need to get this motor timed, and the factory manual for this serial number (2626171) 500 is incorrect. My flywheel has 2 mark's and the front cowl has a sticker for #1 TDC / Max adv setting.

When I use the 2 flywheel marks I get #1TDC lined up and the Dist gear arrow lined up with the other fly wheel mark. The problem is #1 is not anywhere close to TDC and its not at BTDC either. So what now is ask.

Also it looks as if there are 2 scratch marks on the flywheel if I line up 1 of them to the Dist mark #1 is exactly at TDC, but the other does not line up with the cowl TDC mark.

Are these flywheels Key'd to the crank to make sure the marks stay true? ANSWER: Yes.

 

[nickoli1]

Re: 1969 Merc 500e timing (contradicting how' to) I searched fyi, HELP

I moved #1 to TDC not using a gauge, but by feel method and also using the "hand made" mark on the flywheel aligned to the dist mark as a guide. I have a timing light, and used it. What I find is the light will flash with the one of factory timing mark's @ 5 deg mark. No fire. Please help, I sure would like to get this working.

EDIT: im going to open up the Dist cap and attempt to align the #1 by sight and get #1 at TDC by hand to see what is going on, unless someone says otherwise. Im a bit worried if I open the cap i will create a gasket problem. I dont know if I can get a new gasket.

Thanks,
Nick

 

[nickoli1]

Re: 1969 Merc 500e timing (contradicting how' to) I searched fyi, HELP

Well I used my Digital caliper in conjunction with a welding vice grip and some small elastic bands to steady the caliper on #1. I brought #1 close to TDC as possible and zero'd it out. then by hand moved the piston back and forth and found TDC. LOL I should have taken a picture of the setup...!

Then I moved the dist gear arrow as strait as I could get it.

It fired UP, but my damn key would not kill the engine. I had to choke it to stop. I think it might be because I didnt have the switch box grounded.? Im going to assemble it all back and try it again.

As far as the Repair Manual and or Forums and How'to guides, they do not apply to this setup at all!!! The only thing I can think of is if the previous owner or tech replaced the flywheel with another year/type.