I need advice on rebuilding a Merc 500 from 1962

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AaronB79
Posts: 42
Joined: Thu May 08, 2014 7:08 pm
Location: Raymond, NH

Re: I need advice on rebuilding a Merc 500 from 1962

Postby AaronB79 » Sat May 24, 2014 7:35 pm

fergal butler wrote:Mine is a 50 hp with a 400 face plate.

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I also have plans to do a few more when the right engines come up.

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It's starting to get a bit out of hand now :lol:

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It looks like you have a few good projects in the works! I think these engines look great on a homemade Glen-l boat, I just can't wait to get started with mine!

AaronB79
Posts: 42
Joined: Thu May 08, 2014 7:08 pm
Location: Raymond, NH

Re: I need advice on rebuilding a Merc 500 from 1962

Postby AaronB79 » Sat May 24, 2014 7:36 pm

cusoak wrote:Her are a couple of sites that have parts and service manuals. And a Merc. forum with a lot of information.
http://www.johnsoldmercurysite.com/phpBB3
http://www.johnsmcintoshvintagemercuryoutboard.com/
I used them to help me get my merc 400E 45 hp running.
Jeff


Thanks for the help, Jeff.

AaronB79
Posts: 42
Joined: Thu May 08, 2014 7:08 pm
Location: Raymond, NH

Re: I need advice on rebuilding a Merc 500 from 1962

Postby AaronB79 » Sat May 24, 2014 7:38 pm

gdcarpenter wrote:Compression test #1 job - if 120 psi +/- engine innards pretty good and worth further investigation, if low, the unless you want to tear down the engine, part it out.

Dropping the magneto and if not replacing, at least filing, cleaning and gaping the points, hopefully replacing the condenser, doable to try and get spark.


I'll give this a try. The previous owner told me he lost spark, but I didn't think it would be that hard to fix. I didn't realize the parts were so hard to come by. Thanks

gdcarpenter
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Joined: Tue May 05, 2009 12:18 pm
Location: Raleigh, North Carolina

Re: I need advice on rebuilding a Merc 500 from 1962

Postby gdcarpenter » Sat May 24, 2014 8:53 pm

Points and condenser should be relatively to find, but even cleaning/ filing them might let you know if that's the problem. Those parts shouldn't cost that much, and if you are going to drop the magneto you may as well have new ones on hand. If compression is good it might be worth a shot.
This is my first, last and only boat build.

http://www.gdzipbuild.blogspot.com

Mhick22
Posts: 3
Joined: Mon Nov 14, 2016 9:46 pm

Re: I need advice on rebuilding a Merc 500 from 1962

Postby Mhick22 » Fri Dec 02, 2016 1:07 pm

fergal butler wrote:It's a straight swap on any of the wrap around cowls blue,red and brown but it won't work on the clamshell cowls. The engine must also have the same number of cylinders as the one the cowling came off.


So the older top cover piece lined up and fit right onto the newer engine flywheel with no problem? And the wraparound cowl is the same size? I'm trying to do the same thing!

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fergal butler
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Location: Co.Dublin, Ireland.

Re: I need advice on rebuilding a Merc 500 from 1962

Postby fergal butler » Fri Dec 02, 2016 2:47 pm

I just know about the red, blue and brown bands not sure if the older white merc's .

Mhick22
Posts: 3
Joined: Mon Nov 14, 2016 9:46 pm

Re: I need advice on rebuilding a Merc 500 from 1962

Postby Mhick22 » Sat Dec 03, 2016 2:27 pm

fergal butler wrote:I just know about the red, blue and brown bands not sure if the older white merc's .


Ok. So you took a blue band 50 hp and put the cowl and top cover from a merc 400 on and it lined up and worked just like that? No other modification required?

BillW
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Joined: Sun Oct 05, 2008 8:03 am
Location: Seattle, WA

Re: I need advice on rebuilding a Merc 500 from 1962

Postby BillW » Sun Dec 04, 2016 10:38 am

This is a little hard to follow, but if your first priority is to get it running, then:

As mentioned above, check the compression.
If it's good, get a service manual. As a minimum, plan to service the carbs, water pump, ignition, & gear case lube.

The folks at http://www.johnsoldmercurysite.com would love to help you thru it.

After it's running, then new decals can make it look like a different model/year, if that is your goal.


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