Re: Mercury 9.8hp fuel line connector
Hi there, I had exactly the same problem with a 6hp Merc60 (1968 model). WHen you take a quick look at the fuel connector it is easy to miss the fact that there are 2 sizes of this style of mercury fuel fitting, and they are almost identical but NOT interchangeable.
One is (I think) 1/4" hose size the other is 5/16" or 3/8" size. My 6hp merc takes the smaller size but like you I bought the bigger one by mistake. It did not fit (quite) through the hole in the cowling to mate with the fitting on the motor. Being a tinkerer I ground down the fitting so it went through the cowling only to find it wouldn't mate properly and it leaked like mad.
The smaller fitting is not so easy to find these days, I got a new one from these guys, who I can recommend 100%
http://store.eastcoastmarineservice.com/product_p/30635t3.htm
Their guide says it is the right one for 1962 thru 1971 3.9 to 9.8 HP models. Your photo has identical styling as my 1968 motor so I guess its similar vintage, looks a bit newer than mine though. Great motors, built like a brick outhouse!
Mine has been running for 42 years with minimal attention, just did a minor rebuild and I'd say good for another 42 years - the only damage and degradation is cosmetic and easily fixed.
The only semi-serious problem I ever had was it wouldn't idle well, and a can of carb cleaner and a quick readjustment of the idle screw fixed that 100%.
I love that they have nothing high-tech, you can keep these guys running with a pair of pliers, a screwdriver and a hammer! (Maybe some duct tape too...)
Good luck!
Neil.
