7.5 Mercury in pieces !!

kenmyfam

Supreme Mariner
Joined
Aug 10, 2006
Messages
14,392
I have just been given a Mercury 7.5 twin cylinder in several pieces. It is all there and appears to be in good shape except 1 piston is scored in a quarter inch wide area about 0.015" deep. from about half way up to the lower piston ring. The previous owner started the disassembly and has since bought a replacement motor due to the upcoming season. His story is as follows.
Out trolling with this motor running, storm coming in on the lake so he fired up the main motor on his 24ft Sea Ray leaving the trolling motor running. Gunned the boat back to the marina to beat the storm with the trolling motor still running. This apparently starved this motor of cooling water and it overheated. When he stopped at the marina the trolling motor cut out. He tells me that it would still start but would not idle at all.
My plan is to replace water pump assembly and thermostats (if it has any) either replace the piston or repair, new rings,the bores appear fine as regards damage but I have not checked them for roundness or concentricity yet. I will rebore myself if necessary. Then put it all back together and try it out.
The serial number is 7206318 and it has a blue band around the hood. Can anyone help identify the year, model etc or give me a link to where I can trace it myself ?? I have always had Johnson / Evinrude to this point so am pretty dumb with Mercury products !!! I will then get a manual for this little motor and hopefully have myself a reliable little troller for the season. Trolling with my Johnson 140hp just does not cut it !!!!
Thank You all in advance for any and all information and advice you can give.
Ken.
 

Laddies

Banned
Joined
Sep 10, 2004
Messages
12,218
Re: 7.5 Mercury in pieces !!

It's a 1983 Canadain built engine and it sound like a great plan they were good little engines
 

kenmyfam

Supreme Mariner
Joined
Aug 10, 2006
Messages
14,392
Re: 7.5 Mercury in pieces !!

Thanks for the input. Do you think it is worth dressing the piston and new rings or should I just replace it ???
 

Robj

Lieutenant
Joined
Mar 22, 2007
Messages
1,441
Re: 7.5 Mercury in pieces !!

I would try and find used parts first. You can quickly spend more than the engine is worth on new parts. I have the same parts engine in the garage but unfortunately I live at the opposite end of the country.

Have a great day,

Rob.
 

kenmyfam

Supreme Mariner
Joined
Aug 10, 2006
Messages
14,392
Re: 7.5 Mercury in pieces !!

I would try and find used parts first. You can quickly spend more than the engine is worth on new parts. I have the same parts engine in the garage but unfortunately I live at the opposite end of the country.

Have a great day,

Rob.

I will see what I can find locally in "used" !!!!
Shame we are not closer in location !!!
 

Laddies

Banned
Joined
Sep 10, 2004
Messages
12,218
Re: 7.5 Mercury in pieces !!

If the damage is not on the lower pistonn skirt and the skirt mics nthe same as the other it will run OK, did you ck the clearance yet? Were is Belle River PM me.
 

kenmyfam

Supreme Mariner
Joined
Aug 10, 2006
Messages
14,392
Re: 7.5 Mercury in pieces !!

If the damage is not on the lower pistonn skirt and the skirt mics nthe same as the other it will run OK, did you ck the clearance yet? Were is Belle River PM me.

Thanks for the info,

Check your mailbox,
Ken
 

Robj

Lieutenant
Joined
Mar 22, 2007
Messages
1,441
Re: 7.5 Mercury in pieces !!

Actually I have an engine like that in pieces also, but it is an older one. Measure the piston size and if they are the same you can have it. I can throw it in a box and send it to you. Just reinburse me for the shipping costs. For me it is junk anyways and if you can use it, you can have it. Send me a PM.

Have a great day,

Rob.
 

kenmyfam

Supreme Mariner
Joined
Aug 10, 2006
Messages
14,392
Re: 7.5 Mercury in pieces !!

Actually I have an engine like that in pieces also, but it is an older one. Measure the piston size and if they are the same you can have it. I can throw it in a box and send it to you. Just reinburse me for the shipping costs. For me it is junk anyways and if you can use it, you can have it. Send me a PM.

Have a great day,

Rob.

Piston is 1.996" diameter. I have just dressed it with a super fine stone in the scored area and it looks pretty good. I have lost about 0.001" diameter in that area. I have tidied up the piston ring groove and the ring sits and moves nicely again. Going to look for a gasket set etc and go from there.
I will send you a P.M. shortly and thank you for the offer.
Ken.
 

kenmyfam

Supreme Mariner
Joined
Aug 10, 2006
Messages
14,392
Re: 7.5 Mercury in pieces !!

Trying to find a gasket set for this motor here but everything seems to start at 30hp ????
Am I doing something wrong ??? in my search at the iboat store ??
 

AMD Rules

Lieutenant Commander
Joined
Sep 23, 2004
Messages
1,707
Re: 7.5 Mercury in pieces !!

You're correct...

The complete powerhead gasket set, is Merc p/n 27-89014A80

iboats doesn't offer gasket sets for that specific motor.

Might be able to get it through your local Merc dealer. It is available at other retailers online.

Good luck!
 

Laddies

Banned
Joined
Sep 10, 2004
Messages
12,218
Re: 7.5 Mercury in pieces !!

On your engine you don't really need a complete set just the port cover gaskets (1 intake& 2 exhaust) 1 carb and a base gasket Mercury packages alot of extra gaskets in the set and is paid well for them
 

kenmyfam

Supreme Mariner
Joined
Aug 10, 2006
Messages
14,392
Re: 7.5 Mercury in pieces !!

Thanks for all the input and info. I am off on a gasket search now !!!!
Will report back what I find. I will hopefully just get the gaskets that I need as well.
Thanks again Guys from a Mercury rookie !!!
Ken.
 

kenmyfam

Supreme Mariner
Joined
Aug 10, 2006
Messages
14,392
Re: 7.5 Mercury in pieces !!

Well after many business trips I am finally in assembly mode. Looking at the exploded view of the block and crankcase I see no gasket listed to seal the joint ??? I have been told that I need to use #314 loctite and to use a primer on it first.
Any thoughts or advice on this.
Thanks in advance,
Ken.
 

AMD Rules

Lieutenant Commander
Joined
Sep 23, 2004
Messages
1,707
Re: 7.5 Mercury in pieces !!

You're correct... no gasket.

Original service manual states the following:

"Coat joint face of crankcase with Gasket Sealer (C-92-28804) for metal-to-metal contact"

Modern service manuals use this wording:

"Clean crankcase sealing surfaces according to Loctite Master Gasket instructions. Apply a continuous bead of Loctite sealant along the inside of the mounting bolt holes of crankcase cover."

Merc p/n 92-12564-2 (Sierra 18-9003) which is equivalent to Loctite 518. The Loctite 7649 is a surface treatment (primer).


.
 

Attachments

  • 18-9003.jpg
    18-9003.jpg
    9.9 KB · Views: 0

kenmyfam

Supreme Mariner
Joined
Aug 10, 2006
Messages
14,392
Re: 7.5 Mercury in pieces !!

That confirms it then. Thank You.
Onward with the assembly as soon as I get some.
 

kenmyfam

Supreme Mariner
Joined
Aug 10, 2006
Messages
14,392
Re: 7.5 Mercury in pieces !!

Well got finished with the rebuild (almost) and guess what...... No Flywheel !!
I am frantically looking for one so I can try it out.
 

kenmyfam

Supreme Mariner
Joined
Aug 10, 2006
Messages
14,392
Re: 7.5 Mercury in pieces !!

Well I got a flywheel on e-bay for 15 bucks. It is now in place. Just trying to find the nut for it now. Then add impeller, put on starter assembly and we will see what happens !!!!
 

kenmyfam

Supreme Mariner
Joined
Aug 10, 2006
Messages
14,392
Re: 7.5 Mercury in pieces !!

Further question. Not sure if I am missing something ????
#1. I have no idea where the 2 wires from the kill switch connect to
#2. No idea where to connect the brown wire from the switch box.

If I get that sorted then it is on with the lower unit and try it out.
Thanks in advance for any and all info.
Ken.
 
Top