3.5 mercury

HomeyClown

Cadet
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Jul 5, 2021
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6
I got a 3.5 4 cycle mercury from a relative in a bag. The rod was broke in half. It must have been running synthetic when it went cause everything looked mint condition with the exception of evidence of HIGH heat, the shutoff hose bracket was melted and the impeller was very wasted.

well I replaced everything (rod, piston, rings, impeller kit, spark plug) with oem, tohatsu and put it back together. Runs like crap, the carb was nasty so I swapped with a chinese, same same so put the oem back on. I did a compression check, its 60, I read on this site there is a decompression thing but I certainly cannot see one. Runs like low compression. I put a leak back tester on it and it shows everything is pretty much fine, leakage is coming out of the oil fill which would be rings.

I am trying to figure out what direction to go now, do I walk away, do I buy a block,(perhaps cylinder warped due to heat) or do I buy a short block (cheaper than a total outboard but not by much). I really wanted to put this motor on my inflatable boat but I have to get it working first. Any suggestions would be awesome!


Here is a link to it running as good as it gets. no throttle control with two different carbs, old and new exactly the same. All I have to go on is the 60 psi compression check. Fuel is being gravity fed directly into the carb. Im thinking there could be some massive air leak somewhere but I certainly didnt see anything or extra hoses. The carb has two barbs on top but only one hose and that hose just dumps out the bottom of engine it looks. The pic of parts is the old parts showing heat damage, disregard drill, another project.

https://drive.google.com/file/d/1P7NtuUuoozOGfrDcekKYU6eCvJ6j_m8k/view?usp=sharing
 

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racerone

Supreme Mariner
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Dec 28, 2013
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38,411
Parts book seems to show automatic compression release on the camshaft.----Give me a smooth running OMC 6 hp from the 60's and 70's to rebuild.---Great motors they are..----These small 4 strokes are a " throw it away " item in my opinion.
 

HomeyClown

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Jul 5, 2021
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Parts book seems to show automatic compression release on the camshaft.----Give me a smooth running OMC 6 hp from the 60's and 70's to rebuild.---Great motors they are..----These small 4 strokes are a " throw it away " item in my opinion.
yep I just didnt put two and two together when I saw it. Im starting to think your right on it being disposable. It certainly didnt take much to put it together. Thats why I dont think I messed anything up but I certainly could have.
 

HomeyClown

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Jul 5, 2021
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Like I said, it looked really good, so I didnt even think to hone the cylinder. I wonder if that would get the compression up there. Or maybe the cylinder is just toast from the heat?
 

pvanv

Admiral
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Apr 20, 2008
Messages
6,567
The decompressor is why you're low. Is the vacuum line for the fuel pump blocked, or is it leaking?
 

HomeyClown

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Jul 5, 2021
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The decompressor is why you're low. Is the vacuum line for the fuel pump blocked, or is it leaking?
I just went out and hooked the pump up and ran my tank to it like it is supposed to be vs gravity fed directly into the carb bowl and it ran the same. I am using a drill with a clutch connected to the nut on top of the flywheel vs pull starting with the handle. My arm would have given out long ago. I also think I was turning the flywheel fast enough to disable the decompressor and was still getting 60psi. Wondering if the heat did something to the cylinder or if I should have honed the cylinder even though it looked fine. This engine doesnt look like it has many hours on it, just a mishap by running it after the cooling impeller failed. Have you heard of heat messing with the cylinder?
 

HomeyClown

Cadet
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Jul 5, 2021
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No oil cooked my lawn mower.
The powerhead was in a box disassembled so I dont know the oil status but due to lack of scoring and everything looking fine other than the heat damage my guess was that the owner was using a synthetic oil that held up fine in the heat, till the piston rod gave out. Thats my guess.
 

HomeyClown

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Jul 5, 2021
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Glad these things are easy to work on. No idea what was going on, must have messed something up. Pulled it apart, honed the cylinder, measured ring gap, all looked perfect same as before, put it together and



Like an internet guy says all the time, we do it right...because we do it twice.

Thanks for the feedback, if you see anything concerning please let me know. Those two little holes about half way up have me puzzled but never saw any documentation talking about them.
 
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