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    115 6c TOP piston cylinder issue

    There is a springy retaining ring under the bottom yoke. To remove the swivel pin, you would have to remove the upper motor mounts, by splitting the exhaust extension. You can leave the yoke attached to the motor mounts and pull the swivel pin up and out, after removing the retaining ring...
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    Impeller stuck on drive rod, got hot and melted the impeller a little.

    Merc water pump bases melt from the heat of the impeller rubbing against the wearplate. It is from lack of water. The upper pump cover seems to be more resistant to the heat for some reason. I do not know what the newer resin hubs on the Merc impellers will do under those circumstances. If...
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    125 HP fails to rev up

    Look at the markings on the heads of the water jacket cover bolts. They are likely grade 5. Look up the torque spec for a grade 5 (or whatever they are) for a 1/4-20 bolt and see what it says. Torque the bolts from the center out, tightening the center ones, then the next "row" up and then...
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    Starter not engaging

    Easy test. Put voltmeter with battery in DC volts setting. Read voltage. Start motor and set to high idle. Read voltage again. Voltage while running should be higher than voltage not running. Also, with engine running, set voltmeter to AC voltage and read voltage at battery. If you read...
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    Force Air Filters, or lack thereof

    There are newer products to line the cowling with to reduce noise, that won't flake off. Self stick foil/foam insulation comes to mind.
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    Mercury 4-stroke Gas leak

    Sometimes the floats just stick, after a layup. They likely get better after use. If it persists, you may need to revisit the carb.
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    throttle cable and idle adjustment 1986 Mercury 35 hp 2-stroke

    Merc has a specific way to link and synch it's motors. I therefore think a Merc Service Manual is a good idea for you. Generally, you set the idle pickup timing to spec, and adjust the carb to open as the timing hits that timing specification. You then set max spark advance. You set these...
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    115 6c TOP piston cylinder issue

    Sierra used to make motor mounts. They were all rubber, vs the rubber and metal of the OEM stuff. I used them and they were fine. They were about $50 ea. The top motor mount bolts were grade 7, 9/16 fine thread if I remember correctly. I had to cut them, as the motor mounts could not be...
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    115 6c TOP piston cylinder issue

    Five the the holes should be the same size. The 6th hole will be larger, since it has no insert. I would say you have white plastic inserts in the pictures provided.
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    Any reason to fix my wiring kludge?

    Gee, if the OEM wiring harness is going bad. You could replace it. Your spark vanishing is bad, no?
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    Mercury 4.0 hp

    Gee, change the engine oil if a 4 cycle motor. Change the gear oil and clean the carb. Run her a bit and then rebuild the waterpump.
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    1996 115 Crossflow Milky Plug

    Gee, 1200 RPM seems awfully high. She will slam into gear, no?
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    Troubleshooting Bennett Trim Tabs

    Trim tabs are often an add-on item. First look for a separate wire on the battery. Failing that see if you can trace the wires from the pump to electric supply. Remember, trim tabs are hydraulic in the up direction, and spring loaded for down. So you will generally only have 2 wires on them.
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    115 6c TOP piston cylinder issue

    No, bleed inserts are small black plastic restrictors that fit under the transfer covers. At least I think they go under the transfer covers. It has been a long time since I looked at an IL6. Number 3 in this diagram. They help with idle quality...
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    Mercury 50 HP Electrical Issue

    CDI electronics likely makes parts for your motor. They used to have a troubleshooting guide as well. Failing that a Mercury brand service manual should give resistance specs for the stator.
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    115 6c TOP piston cylinder issue

    While you have it apart, check the swivel pin for binding. If those two bushings get corroded the motor will be hard to steer, and if it is all together, you will hate yourself. Ditto on the top and bottom rubber motor mounts. See if you can thru drill the broken water cylinder head water...
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    Starter not engaging

    If it is a permanent magnet starter, it must be put back together with the magnet in the same orientation, or it will run backward. It makes sense to match mark the ends to the center magnet.
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    fuel sender install w/sealant or dry

    Regular form-a-gasket is not usually gasoline resistant. It will disolve and cause more trouble. Permatex makes a gasket dressing that is impervious to gas. It is not real common in stores, so it pays to get it's stock number and then see who has it. Use a rubber gasket and the dressing...
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    Starter not engaging

    If you hook up the jumper cables backward, the motor will spin the wrong way and not engage the bendix.
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    Type of boat

    Chrysler motors did not come on too many boat types, and Chrysler did own some boat makes. You might start there. I presume there is no HIN stamped into the starboard side of the transom? Also, if you can find out the year of the motor, the boat year may be the same.
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