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  1. W

    1989 60hp water inlet tube

    Hi Everyone, After pulling the powerhead on my 60hp Merc (OB240262) I noticed a rubber sleeve sitting half way up the copper water tube that I had never noticed on previous impeller replacements. I have trawled the internet and can see plenty of exploded diagrams with this part but can't find...
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    Powerhead removal

    The driveshaft was the cause, there was corrosion on the splines even though I had applied a thin layer of grease before assembling after the last impeller replacement a year ago. I've taken the lower unit off and noticed a rubber O ring perished on top of the water pump housing so assume that...
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    Powerhead removal

    Thanks to everyone who gave their input into this. It took an electric hoist, DIY gantry, oak wedges, ratchet straps, 5 cans of penetrating oil blasted up the driveshaft with compressed air, 3 hours with an air hammer and pry bars and the sucker finally gave up and let go. May as well replace...
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    Powerhead removal

    If I could get the powerhead to lift a little more I could get to the driveshaft but at the moment the casting on the exhaust plate is obstructing any access. I'm going to get the air hammer out tomorrow and while I've got the tension on the hoist I'll see if I can use some vibration on the...
  5. W

    Powerhead removal

    All 8 nuts have been removed without any fuss which was a nice surprise. What's baffling me is that I had the lower unit off last year to replace the impeller like I've done for the past 5 years and I greased the splines before assembly. I'm keeping the tension on constantly now, just wish I...
  6. W

    Powerhead removal

    Thanks for you replies, I've located and removed all of the nuts that secure the powerhead. The reason for attempting this is in an effort to free the driveshaft from the powerhead as it appears to have welded itself which I found out after attempting an impeller replacement. I can see a gap...
  7. W

    Powerhead removal

    It's an original Mercury service manual covering models 45hp to 115hp from 1965 through to 1991.
  8. W

    Powerhead removal

    Hi Everyone, I have a 1989 Mercury 60hp OB240262. I'm attempting to remove the powerhead and the manual calls for the shift link attaching nut to be removed but there's no picture for reference and when I look around the area I can't see anything obvious. I've loosened 8 x nuts around the...
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    Exhaust leak 1989 Merc 60hp

    I've been down to my mooring this morning and rocked the power head but movement is minimal. When I lift the power head I'll just go ahead and replace both engine mounts and any gaskets and I'm sure a few other parts will want replacing along the way. I suppose it's to be expected from a 35...
  10. W

    Exhaust leak 1989 Merc 60hp

    Thanks for everyone's input on this, I've been through my manual to understand the power head removal part, but I can't seem to find any reference to engine mounts, would any of you happen to have this information, and I ow why it's omitted from a repair manual?
  11. W

    Exhaust leak 1989 Merc 60hp

    I'm on my mooring now for the season and would rather avoid starting something that could bite back if anything's corroded on, which I suspect it would be being a vintage motor. I dry store my boat at home over winter which is when I prefer to carry out any overhauls with more time, under cover...
  12. W

    Exhaust leak 1989 Merc 60hp

    Thanks for taking the time to answer and to look at alternative solutions. I need to pull the power head at the end of this season anyway so I'm assuming that there's no chance of damaging anything if left to run like this for the next 6 months?
  13. W

    Exhaust leak 1989 Merc 60hp

    Hi, I appear to have an exhaust leak coming from the back of my outboard towards the transom bracket. I only found it because I noticed a small splattering of oil in the splash well and then noticed exhaust water dripping down the back of the leg. I've attached a photo of where the leak is...
  14. W

    1989 Mercury 60hp primary pick up adjustment

    Thanks for the advice, it certainly helped me. Once you get your head around the link and sync procedure it's not that complicated and well worth doing as it's made a massive difference, especially to fuel economy in my case. She now idles smoothly at 850rpm in neutral and 700rpm in gear with...
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    1989 Mercury 60hp primary pick up adjustment

    Thanks for the information, you've cleared that up in my mind now. Does it matter where the primary adjustment screw starts? I honestly panicked when I realised I'd turned the wrong screw by mistake and don't know where I ended up, it's screwed in just over half way at the moment. Would it be...
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    1989 Mercury 60hp primary pick up adjustment

    She's an old girl for sure, but only 10 years use out of the box. This old Merc, along with other relics, was found by a family member in its original packing crate in 2013 in a corner of an old engineering Workshop that we had acquired at auction. It's just the conflicting information in my...
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    1989 Mercury 60hp primary pick up adjustment

    I own a 1989 Mercury 60hp 2 stroke and although this motor is almost vintage she's been very well looked after, serviced annually and owned by myself for 10 years. Long story short, due to some niggling issues last year, I carried out an overhaul of the fuel system, replaced the CDI box, coils...
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