Opinions on 1964 Merc 500?

[JACQUES]

I have  a SELOC book from 1965  (Merc 3-4 cyl) onward but it does cover points/distributor  Tupe 1 ignition  used in 1964 models so if you need info just flag it.. back in 2 days . I can scan and send  some  sheets  via e-mail  JPG

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[kmead]

Thanks very much for the kind offer, Jacques. I purchased an online version of the Seloc manual, so I think I should be good for instructions. It turns out, the motor was actually built in 1965. I also found a source for the points, condenser, and many other parts for old mercury’s at https://www.fergusonpoolemarine.com/.

[kmead]

While taking apart apart the lower unit, I’ve reached an impasse. The online manual I have says I need special gear housing cover tool
#(91-30291A2) to remove the gear housing cover. (Looks like a notched ring, with the arrow pointing to one of the notches.) Here are pictures of the cover and the tool.

I found the tool on eBay for $75, but is there a cheaper homemade way to get this ring off?

[JACQUES]

is it leaking  why mess with it ?  did a pressure test on the gc ?  i would just drain and refill get that beaty running   you can fix gc later

 

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[kmead]

Just thought I’d do it while the lower unit was off the motor. Didn’t do a pressure test. Just grungy!

[JACQUES]

if it works do not fix it….check for water and do pressure test to see which seal COULD be leaking.

Bing Videos

 

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[kmead]

Yes I see your point.

[DAVID]

make sure the thrust wsher is on before the prop orit will run into the nut. looks like it has in my pic see if the prop is worn in that area.

[kmead]

Good eye David.
I thought it was odd that the propeller could move back and forth about 1/2” along the shaft, and as I was disassembling it, I discovered it was missing #69, the cupped washer, according to this illustration. It does have the thrust washer, though.

[DAVID]

that is the old style . new style has all 3 parts in 1 unit much better use that one. if the motor cavitates you may have to replace the worn prop and fill the gap in the gear case with J-B weld to leave a 1/4in gap or less.

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