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    Non conventional issues.

    That is often called an airbox.
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    NO SPARK 1988 mercury 100HP outboard Sea Ray seville

    If your rectifier is shorted to ground, it can hinder the spark. You might disconnect the yellow wires from the rectifier and insulate them. Repeat the spark test.
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    Non conventional issues.

    When you say intake, do you mean crankcase cover or something else?
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    Prop Locking Question (Reverse Locking Cam?)

    The slinger should be installed over the driveshaft, on top of the waterpump housing. It is heavy rubber and will not move on it's own. Your driveshaft may have a groove for an oring, just below the spline. Some do, some don't. If you have the groove, install and oil an oring. Mercury's...
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    What is different about newer primer bulbs?

    My newish primer bulb seems to be full of a spongy plastic-like material, like a kitchen scrubber, which keeps the primer bulb expanded and helps the primer fill. Dog toys have it as well. I have not had an issue with that primer bulb on my Johnny 150hpv6.
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    Prop Locking Question (Reverse Locking Cam?)

    Inline 4 and 6 cylinder gearcases from the 70's and early 80's of the correct shaft length will fit your motor. Most of the shaft lengths were 20" on those motors. The gearcases had a locking tab, with a "donut" shaped nut that screwed into threads of the hub of the gearcase. By this point...
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    Prop Locking Question (Reverse Locking Cam?)

    If you get the gears shifting, you will want to set the gearcase to neutral and the control to neutral, for reassembly. In my mind that reverse lock is optional. Just don't quickly rev up the motor in reverse, and she will stay down, well enough. If you cannot get the gears to shift, you...
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    2002 225 Optimax - Overheating at idle only

    Idle temp control is managed by the thermostats. Starting at about 2000RPM the poppit valve controls the temp. Therefore, I would check the thermostats. If the 'stats check out, Mercury motors will overheat at idle, if the bottom part of the waterpump impeller is damaged a bit. They will...
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    Need Help Testing Rectifier Please

    A full wave rectifier is composed of 4 diodes wired in a bridge. The internet will give you a diagram. There are two connections to the stator wires and a connection to -12VDC and another connection to +12VDC. Mercury uses rectifiers that have the case ground connected to the -12VDC. Diodes...
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    Prop Locking Question (Reverse Locking Cam?)

    That cam is purely to lock the motor down in neutral and reverse. It is there to keep the motor from kicking up when you suddenly slow down or engage reverse. I would remove it until you get the gearcase straightened out. I would also pump in new gear lube before doing anything else...
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    Need Help Testing Rectifier Please

    That looks to be a voltage regulator. They are not as easy to test as a rectifier. Actually the test may be to measure the voltage at the battery under different RPMs.
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    Polyester resin over floatation foam

    I have always heard that polyester resin will generally melt foam, except for certain kinds of foam. I think you should try a sample. Epoxy resin will not melt foam.
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    Outboard in the Lake

    Freshwater is not hard on motors, at least compared to salt water. Also, the legacy of 2 cycle oil tends to protect them from fresh water for a while. You do need to get it running PDQ. Check for spark and clean the carb. I expect the engine to have magneto ign, so clean the points and check...
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    1988 Bayliner Restore or Replace

    Gee, that 1990 SeaRay is priced about double what I would expect. It should be in the "any old boat is worth at least $2500" category. I had a 19' 1988 SeaRay Sorrento. It had quality control issues. Some parts of the boat were very well built, other parts were poorly built. The hull even...
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    Prop Locking Question (Reverse Locking Cam?)

    KJM, Those are the attachment points for the shift and throttle linkages. He needs to make sure the gearcase shifts, before he installs the shift cable on that post. The design of the throttle arm assures it is in the way of any manual "exercise" of the shift mechanism, hence, it needs to be...
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    Prop Locking Question (Reverse Locking Cam?)

    The gearcase should not "stick" in any gear, especially reverse. I would drain the gearcase oil and refill with the correct stuff. Any marine gear oil for mechanical shift motors will work. Wallyworld usually carries it. Failing that a marine store will have some. You will need about a...
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    NO SPARK 1988 mercury 100HP outboard Sea Ray seville

    Go to the crowleymarine site and punch in your serial number. It should give you an exact parts list.
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    Prop Locking Question (Reverse Locking Cam?)

    When was the last time you changed the gear oil? The shifting mechanisms do not usually lock up as you describe. Dropping the gearcase will not expose any shifting cams.
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    Broken Skeg

    I have not priced out a new gearcase housing, but the work involved is swapping the internals plus the special tools and know-how necessary will make it difficult. At least price out a new gearcase from SEI. Mercruiser used to rebuild outdrives for $2K. At that time SEI sold new ones for...
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    1995 Skeeter ss140 - 135 Mercury Black Max G179207 Constant Alarm

    That year motor had oil injection. I would suspect alarm is from that, if it is not from overheat.
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