Mercury 402XS restoration help

[lftmx3]

Hello, I am attempting to revive a 1976 402XS 40hp (essentially a pull start only 402 with the Quicksilver race lower.) The motor has seen very little use over it's life, it sat in a basement for the last 30 years. Parts I've replaced so far: all rubber hoses, trigger assembly, all wires, spark plugs. I attempted to start it today and could only get it to pop a few times by squirting fuel in the chamber through a sparkplug hole. When I prime the fuel line, it seems like fuel is being delivered to the carb because if I continue squeezing primer too long fuel will begin to leak out the front. However, when spark plugs are removed from head they are bone dry. I initially soaked carb overnite in kerosene but I'm thinking I may need to do a total rebuild. I ordered the rebuild kit today. Am I on the right track or could this be something else more serious? Thanks

 

[Chinewalker]

That's a rare bird! It was produced for a dying class (36-Runabout) and wasn't enough to revive the class. It also wasn't competitive enough to bump up to the next larger class (D-Runabout), so there weren't many produced.

I think you're on the right track with a full carb rebuild. Make sure the float is set as per spec in the manual. You do have a manual, yes? The basic OEM Mercury manuals of the day will cover the powerhead stuff well enough (ignition, fuel, etc.). They're not hard to find. A manual for the gear foot might mean finding the old 1965 & prior Mercury manual, as I know that covers the Quicksilver feet. You said you replaced wires - were the originals rotted? It is very difficult to crimp or solder to the old power pack wires and is usually just better off replacing the whole shooting match.

Keep the foot full of grease (I use Lubriplate 105 in mine). Check the water pump impeller, too. The cone on the foot is REVERSE THREAD. The correct tool turns up on eBay from time to time if you don't already have one.

 

[Faztbullet]

Don't try to use this motor on a everyday hull