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You really need the plastic tube that sticks out of the water pump outlet. It is very hard to get the watertube into the pump outlet w/o it. When you say dowl pin, I presume you mean the locating pin between the midsection and gearcase, at the very rear of the gearcase. I never had any issue...

If you have a preload pin it would have been visible on the top end of the driveshaft. Remember to put grease on the splines on the shiftshaft and driveshaft, but not on the ends of each. Wiggle the shifter to make sure it mates. You did put the plastic shiftshaft guide in the midsection...

I always liked the 850. I thought it had good power in a compact size. Since it only had 2 carbs (vs the IL6) it was easier to tune, and I thought it ran very good for a 4 cyl 2 smoker.

You can likely buy a new wiring harness for the motor. Get a part number off crowleymarine and search on it. Sierra used to make one if memory serves. CDI Electronics may have some stuff as well. Check the spark plug wires. They were called "Yellow Tiger Tails" and use to be available from...

Unfortunately, the engine wiring on those older Mercs fails in time. Take a look at it, to see if the insulation is falling or has fallen off the wires. The distributor ign worked fine, but replacement parts are real expensive. The rotor was non-replaceable and $200 or more. The dist cap was...

When rebuilding my '77 Merc 1500 IL6, replacement pistons had 2 keystone shaped rings. These replaced the original 3 square shaped ring pistons.

Gee, to rebuild the waterpump, I use four cement blocks with a wood pad, or I chuck it in my vise. Easy stuff, as the carrying is the hard part.

Scott, This is off topic for your post, sorry. The water separator only holds about a pint or more of water, before it sends it to the carb or FIs as it fills up. I think that the water separators should be used as a maint item to trap the last few oz of water, if they exist. Water of more...

When Dingbat says oil recirculation system, he is not talking about the oil injection system. Modern 2 cycle engines recirculate any pooled fuel and oil to find a place to burn it. Older 2 cycle motors like my Fat-Fifty simply dumped it overboard. On my '98 Johnny 150HPV6, there are two fuel...

On the non PT Mercs, the motor needs to be in forward to tilt it. Power trim Mercs did not have the mechanical lock down rod, of the non PT motors.

The missing ring on the "better" piston (piston 6??) concerns me. Did you find any pieces of it? You might measure the thickness of the ring groove, as it looks like it opened up. A new ring might just fall out as well.. I would be surprised if cylinder 3 and 6 do not need boring.

So, no water in your main tank? Good to know.

Unless you need to replace the top main bearing, you do not need to remove the top end cap. So the stator can stay. The crankshaft connecting rods can be connected with the crankshaft in the block. It is a bit easier with the cap screws, but fingers fit to hold the nuts, as if needed. With...

Jeff, I have always been able to reach the flywheel while holding the gearcase in place. Of course, my speedboat is a low boat, making that easy. If I try to install the gearcase in forward gear, often the shift splines will not align properly and the engine will not shift into reverse or...

So Matt, your plan is to cruise for a while, and then empty the separator canister into a bucket on your boat, refill it with fuel from the tank and repeat? If so, you will introduce fuel and vapors into your cockpit or need to dump it overboard to avoid that. Both are a bad idea as vapors...

I am not sure I follow your comments. Here is my interpretation. Endcaps will slip out once crankcase is split, and endcap bolts are out. If you need to replace endcap bearing, you will need to pull trigger, stator and flywheel. Upper and lower endcap bearings may be different types. Older...

Gee, it sounds like a test is in order. I do not think you have the "Check Engine" alarm. I think that is on the V6 engines only. But you can ground the tan wire on the cylinder head and see if the overheat alarm sounds. Testing the no oil and low oil are a bit more involved. You can simply...

You can pull the flywheel, however, unless you need to remove the end cap, there is no advantage. Make sure you mark the stator wires. There are some pairs which must go to the same switchbox, for Ign to function properly. Plan on installing all pistons into the bores after repairs, and then...

Jeff, you could turn the flywheel to align the splines. A 1/2" socket on one of the outer flywheel bolts does the job. I usually use a lifting eye, with the handle of my ball peen hammer thru it as a lever. You can also move the gearcase rotationally before installing the water tube. That...

Gee, remove and siphon the fuel out of the kicker tank and pour off the water. Spend $10 on an electric fuel pump and siphon the fuel off the bottom of the main tank and pour off the water. A water separator works by allowing the water to settle to the bottom of the separator canister. If...