Merc thunderbolt 400 40hp 1970 Bad Powerhead??? Help!

fixitrodd

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May 31, 2011
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Thank you for you help in advance. I'm at a stand still. Here's what happened?

***** EDIT, It's a 1970 ******

At the beginning of last season my impellar went bad and the motor over heated. I replaced it, hooked up the water for a test and water came out of the water jacket around the spark plugs and ran terrible. If I removed the water it seemed to run ok. Of course no load and only for a second to see what happened.

I put the boat away for a year and started working on it again.

Tonight I tested compression... zero to 5 or 10 on the top cylinder... bottom cylinder 115. I put some marvel mystery oil in to see if I could get some compression. The top cylinder seemed to have even less compression using my finger. The bottom cylinder seemed to increase some (normal amount).

This is my first outboard. I'm not real familiar with the layout but I do know it doesn't seem to have a regular head. Just a water jacket over the top of a block which seems to be know as the powerhead from my research. I don't currently have a book or an exploded view to look at.

I thought maybe a sticking ring but nothing increased with the oil and I did slowly put rope in while it was rotating to make the piston "bounce" a little from the resistance. Old grandpa trick. If it gets cut or falls in just shop vac it out. I use rope to hold valves while changing them a 4 stroke as well. Didn't help.

I'll worry about the water jacket gasket later. I broke the top two bolts so I quite that mess. I'll goop it up if I have too but I'm thinking I have much bigger issues.

There's no knocking, pistons move good, turns over easily "without spark plugs" and oil doesn't increase the now about 0 to 10 psi I have in the top cylinder.

Please help!
 

fixitrodd

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Re: Merc thunderbolt 400 40hp mid 80's Bad Powerhead??? Help!

Re: Merc thunderbolt 400 40hp mid 80's Bad Powerhead??? Help!

Serial number listed on the plate at the steering component is 2877277. I'm not sure what year for sure. I don't know how to tell. Thanks.
 

Big flop

Petty Officer 1st Class
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Apr 6, 2011
Messages
290
Re: Merc thunderbolt 400 40hp mid 80's Bad Powerhead??? Help!

Re: Merc thunderbolt 400 40hp mid 80's Bad Powerhead??? Help!

No compression after a overheat is normally
bad news. You can pull the intake cover
and look at the piston to see if it's
is scored.
 

fixitrodd

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Re: Merc thunderbolt 400 40hp mid 80's Bad Powerhead??? Help!

Re: Merc thunderbolt 400 40hp mid 80's Bad Powerhead??? Help!

i'm assuming that is the plate on the side of the cylinders. I'll pull that off after work tonight and report back. thank you for helping!
 

Chinewalker

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Re: Merc thunderbolt 400 40hp mid 80's Bad Powerhead??? Help!

Re: Merc thunderbolt 400 40hp mid 80's Bad Powerhead??? Help!

Serial number comes back as a 1970 model year...
 

fixitrodd

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Re: Merc thunderbolt 400 40hp mid 80's Bad Powerhead??? Help!

Re: Merc thunderbolt 400 40hp mid 80's Bad Powerhead??? Help!

Wow, ok. 1970. Thanks for looking that up!!!!!!!!!!! Shows what I know!
 

fixitrodd

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Re: Merc thunderbolt 400 40hp 1970 Bad Powerhead??? Help!

I opened up the intake. The top and bottom piston look very similar. I did notice on the top piston the center ring didn't seem to quite touch the cylinder wall at the top of the cylinder.

Is it possible that when it overheated the friction basically wore the rings down and possible part of the cylinder?

I tried putting oil in the cylinder again, a lot of fogging oil, and the psi went from about 10 to 15... I don't know if that helps anything or not.

Is there anything else I can check before tearing it all the way down?????
 

Big flop

Petty Officer 1st Class
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290
Re: Merc thunderbolt 400 40hp 1970 Bad Powerhead??? Help!

If it got really hot-hot, the cylinder wall might
be out of round.
Are the rings free in the piston?
How hot did it get, did the motor quit?
 

fixitrodd

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Re: Merc thunderbolt 400 40hp 1970 Bad Powerhead??? Help!

Yes sir! It diid stop. The rings were very easy to tell they were free on the bottom but the middle ring on that top cylinder didn't seem too be free. I watched the ring while barley moving the flywheel back and fourth.

Out of round would make since the way that top ring wasn't touching I suppose. I've started to tear it down assuming it's a cylinder or piston problem of some sort. It's not doing any worse in pieces. I don't know how to take the motor off the frame. I have most of it tore down now. once I can get it off the frame I can pull the cylinders off.

Any idea where I can download a book or other pics to help me out???

Thanks for your help!
 

fixitrodd

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May 31, 2011
Messages
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Re: Merc thunderbolt 400 40hp 1970 Bad Powerhead??? Help!

How do you separate the motor from the drive unit. I took all the bolts I could see under the plate that was screwed on with Phillips screws and bolts on the top. Do I have to remove the drive?

I've stripped it down pretty good but can't get it out of there!!!
 

Mi duckdown

Commander
Joined
Apr 14, 2007
Messages
2,575
Re: Merc thunderbolt 400 40hp 1970 Bad Powerhead??? Help!

An OEM mercury marine service/repair manual would be your best friend, at this point.
 

fixitrodd

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Re: Merc thunderbolt 400 40hp 1970 Bad Powerhead??? Help!

OK, I found the book for $5 download. I got it out and found the bad news.

1. Rings on the piston are really stuck... wish that was it.
2. Hole in the top of the cylinder right next to the spark plug hole :facepalm: Great!!! So, from some of the troubles this engine has caused people I'm not even sure if I want to put any money in it unless I can find an inexpensive power head. ....

Any ideas where they are for the least money??

Thanks to everyone who offered advice. Looks like the mystery is over.
 

Big flop

Petty Officer 1st Class
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Messages
290
Re: Merc thunderbolt 400 40hp 1970 Bad Powerhead??? Help!

OEM / Original Equipment Manufacturer, or
Manuel by mercury marine.
Did you remove the lower wrap around
cowel and remove the 8 nuts, I think?
I haven't seen a 400 merc for many years
so hopefully someone will post with more
recent hands on.
Try E-bay for Manuel.
 

fixitrodd

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May 31, 2011
Messages
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Re: Merc thunderbolt 400 40hp 1970 Bad Powerhead??? Help!

There was one smaller bolt that I thought was just holding the framing on... I was wrong :)
 
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