mercury 4.5 hp problems

ronrobbie7

Seaman Apprentice
Joined
Sep 21, 2006
Messages
42
Hi, I've got a 1976 4.5 hp mercury outboard. When I try starting it the cord pulls back hard and rips out of my hand almost every time. I don't know what's causing this but any help would be appreciated cause my fingers are starting to hurt.
Thanks Ron
 

emckelvy

Commander
Joined
Jan 16, 2004
Messages
2,506
Re: mercury 4.5 hp problems

Ron, many times this is caused by a sheared flywheel key. If the key shears, the flywheel is out-of-synch with the ign and can cause problems such as backfire or kicking back.

You'll need a harmonic balancer puller or other suitable gear puller and some grade-8 puller bolts to get the flywheel off.

You can look up parts here, just open the parts diagrams with your motor's serial number range:

http://www.mercruiserparts.com/SelectModelType3.asp?class_id=2

While you're in there, take a look at the points, if they look gnarly just clean them up to bare metal, degrease, and gap to .020". This type of ign system "makes" to fire and the points handle very high voltages, so they do tend to look a bit crispy.

When you're done, torque the 7/16" flywheel nut to approx 35 ft-lb. and you're done.

HTH.............ed
 

Laddies

Banned
Joined
Sep 10, 2004
Messages
12,218
Re: mercury 4.5 hp problems

While your in there change the insulator block on the point stud that's what normally make then kick that bad.
 
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