75 HP Mercury 2 Stroke 2002 ELPTO

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Apr 6, 2018
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Hello everyone!

I bought a used pontoon boat,,,, actually just for the trailer that was included. It is a 24 foot pontoon and a newer Triton cantilever trailer. I got a great deal because the guy couldn't get the boat started and didn't want to deal with it anymore. He said someone told him the motor was bad. He said a friend just listened to it crank and never took the cover off the motor, :eek:

It is a 2002 75hp Mercury 2 stroke ELPTO

It had no battery on this boat I just bought,,,, so I figured since I have another pontoon boat,,, I bought a new extra battery (1000 MCA) figuring it is good to have an extra battery for my currently running boat if this motor is bad. It labored cranking, the new battery was fully charged though.

I pulled the cover and seen the bendix gear was stuck up on the flywheel. I tried to get it down but it was jammed. I pulled the spark plugs and it cranked ok. I put my thumb over each cylinder while the engine cranked and felt pressure. I re-installed the plugs and cranked it again and it was laboring. This thing has sat for 5 years so I got a gas can with fresh gas and hooked the line to the fresh gas. Still no luck starting but it would still crank very hard (slow crank)

I sprayed the carbs with carb cleaner and it fired up for a second then died. Seems it wasn't getting gas.

Removed the fuel pump and it was full of gunk and the diaphragms were worn. I ordered a rebuild kit and I am waiting for it to come in.

I removed the starter and felt it grind while spinning by hand. Took it to the local auto parts store and he hooked it up to the starter tester and it was grinding horribly.

I bought a new starter and have that installed.

My question is, while I am waiting for the new rebuild fuel pump kit, is it safe to check the compression with the fuel pump off the motor? I know the pump works from cylinder vacuum so I thought it may be an issue checking the compression with the fuel pump off, essentially it is a huge vacuum leak correct?

I should have checked it before but the starter was struggling and didn't think it would be successful.

I mean if this thing is no good, so be it, I did not pay a lot for this setup but I will put money into it if I think the reward is greater then the risk.

Thoughts? Ideas?
 

racerone

Supreme Mariner
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Dec 28, 2013
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Go ahead and test compression now.----That hole in the crankcase will have ZERO to do with compression in the cylinder.---Crankcase compression has nothing to do with cylinder compression.
 
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Well I checked it today, 100 PSI each cylinder,

So, I have compression, spark and hopefully when the fuel pump rebuild kit arrives it will have gas which means it should start.

Fingers crossed
 
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Apr 6, 2018
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Well, fuel pump rebuilt and that did not do it,

It cranks and back fires and will not start

Any ideas where to look at next?
 

Willyclay

Captain
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I sprayed the carbs with carb cleaner and it fired up for a second then died. Seems it wasn't getting gas.

Recommend you try spraying the carb throats with premixed fuel, not carb cleaner, and try to start it again. If it tries to run, then I believe you need to clean the carbs with an overnight soak, spray cleaner after soaking and a gentle air blow-dry. While you have the carbs off for cleaning, test the fuel pump delivery into a container to verify it is okay. Good luck!
 
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Apr 6, 2018
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Funny you posted that!!!

i pulled the flywheel today and the key was sheered!!!
 

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Merc dealer ordered me a new woodruff key which from Merc comes in a set of 2

part number 28-91800 @$2.15

They said it should be in tomorrow or Thursday, STAY TUNED!!!
 

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Last edited:
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Apr 6, 2018
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I have read on the forum that I should “lap the key to the crank” using a valve lapping compound?

Can someone give me details on how this is done?
 

racerone

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You lap the flywheel tapers.-----You do NOT lap the key to the crank !-----The key locates the flywheel for proper timing.-------The flywheel is DRIVEN by the tapers when properly torqued.----So leave the key out.----Smear a little fine grinding compound on the taper.-----Install the flywheel and rotate the flywheel back and forth.----Inspect the tapers.-----You will see when you have a proper fit by the appearance of the tapers.-----Lap till both look the same.-------A little compound is all that is required or needed !!
 
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You lap the flywheel tapers.-----You do NOT lap the key to the crank !-----The key locates the flywheel for proper timing.-------The flywheel is DRIVEN by the tapers when properly torqued.----So leave the key out.----Smear a little fine grinding compound on the taper.-----Install the flywheel and rotate the flywheel back and forth.----Inspect the tapers.-----You will see when you have a proper fit by the appearance of the tapers.-----Lap till both look the same.-------A little compound is all that is required or needed !!

Haha I meant flywheel to crank,,,, I was wondering why do it since this is the flywheel that came off the motor but I guess there may be small imperfections that need attention.

Thanks for the reply
 

racerone

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It is a standard procedure for me .----I guess a mystery to some folks.
 
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Well, baby steps,,,,

It runs but no water from the weep hole. Impeller kit on order.

just curious, is it possible that the lower key sheered as well causing the shaft not to spin and pump water?

There was no water in or near the Impeller when I disassembled the lower unit to get at the impeller.

I would think since I had water on full blast that some water would have made it to the impeller???

I didn’t run it long because it wasn’t pumping water

Anything for advice I can check while the kit is on order would be appreciated?????
 

racerone

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No lower key on that motor.----Water drains from outboard systems when not running.-----Was the flywheel nut loose when you took it off, yes or no ?
 
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No lower key on that motor.----Water drains from outboard systems when not running.-----Was the flywheel nut loose when you took it off, yes or no ?

No, but,,,,,,,,,, I was able to break it loose with some firm tension holding the flywheel
 
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