68' Mercury 1000 Thunderbolt 100HP Rebuild

[polariskid23]

Hello, I am new to this page and recently have acquired an old Merc that was on a Rayson-Craft. I am definitely keeping the boat. The motor has the original controls, tach, key but does have updated steering. The previous owner really screwed up the foot and disassembled it and I am not sure if all the parts are even there. They did not maintain it well. I haven't been able to do a compression test on it yet, that will probably dictate if I will try to get it running or not. The fuel lines are also shot on it, but other than that it seems pretty clean. I am familiar with newer outboard motors but this is the first time I have worked with something this old. I could really use some general knowledge of this motor and if it is worth trying to get running. I am not looking to completely restore it, just get it running for the summer so I can test out my boat after I re-glass it. If someone is interested in it, shoot me an offer!

[Capt.Insane-o]

Gearcase looks pretty crispy, sent ya a pm.

[eli]

ouch good luck with it

[polariskid23]

I finally have the motor off and was fooling with it a little until I build a stand. That is that piece that is in between the lower unit and the top of the motor. Never really seen something like that before. Any ideas or places where I can get good information on these motors?

272629272630

[Capt.Insane-o]

That's an extension kit to make it a 20 inch. Lots of service manuals on e-bay, and parts @ www.oldmercs.com (http://www.oldmercs.com) and johns old mercury site. It takes a lot of love and money to restore an old motor like that. The cool factor can't be beat though.

[largecar91]

The old 100's are great motors when they are working right. If it has good compression then just replace the fuel lines and the wires cause the insulation is probably toast . Clean the carbs, put good fuel and oil in it and fire it up. the problem with the old inlines is they wont last on cheap fuel and they need good water pressure or you will cook pistons. A lot of your newer marinas dont like screwing with these motors but there are still plenty of people that know what they are doing when it comes to inlines. Your motor is a short shaft so if it were me I would get rid of the extension and go with short shaft. If the lower unit had a driveshaft coupling on it then it has a short shaft lower unit. The lower are easy enough to come by and inexpensive, I have several.

[polariskid23]

I have been trying to find information on these extension kits but cannot find any. It was in pieces when I got it so I am not sure what all came with it to make it an extension. Does it mean that the drive shaft is longer or is there an extension of that somewhere else? It looks like all the bolts have extension and there is a can extension for the exhaust, but I am not sure what is going on for the shift link then. The shift rod looks like it might have broke but I am not sure. Anyone have a picture of what this should all look like? I am waiting on my manual to get here.

[Capt.Insane-o]

Extension shaft is probably stuck in the crankshaft yet.

[polariskid23]

There is a piece floating around in there but I didn't know that's what it might be. How would I get to that? How doI get to the exhaust can for removal?

[Capt.Insane-o]

There is no real need to remove the exhaust can on that motor. The extension shaft can be a bit of a bugger to get out. I have a cut off x tra long driveshaft from a v6 and pack the splines up good with spline grease and wobble it around until it falls out. Otherwise your stuck pulling the powerhead. With a motor that age it's wise to replace the lower crank seals and water tube grommet anyhoo. You can give me a call tomorrow if you want 989 362 8641 ask for Lynn and someone will come get me to the phone.

[polariskid23]

So pretty much do my best to get it out through the drive shaft area. I am also going to have to get new bolts for the whole lower unit except for one. Would you happen to be in the Tawas area, Capt. Insane-o?

[Capt.Insane-o]

Yep, right out on the point.

[polariskid23]

I got the extension out. Are there extensions for the shift rod and water tube as well?

[largecar91]

there should be an extension for shift shaft, drive shaft, water tube(or a new longer tube).

[polariskid23]

273821273822

I do not know the order in which these go in and if I am missing more pieces.

[polariskid23]

I finally got a battery and did a compression test. 90-92 across all cylinders. That is with no extra lube going through and in 35 degrees. I bought some parts motors that I can get fuel lines and electrical from. Also they had mids and foots on them with props. They are long shafts with I hope I can use a bunch of parts, I bought them cheap.

[polariskid23]

I have got all my parts together and am almost ready to put it back together and try to run it. I m missing one stud though in the mid-section. It came out with the extension kit. It rusted into the steel adapter. I have tried the double nut job but its not budging. I also have two other mid-sections and none of those studs are budging either. Any ideas of where I might be able to find some?

[polariskid23]

I figured out my stud situation and got the foot on. It was in forward so I took it off and found neutral..I think. Finding the gears in the lower unit is pretty difficult. When I did find neutral, I was getting ready to put the box in neutral and for some reason it locked up. So now I have the box apart and I cannot really find why it was stuck. Nothing was broken. It was hard to shift back and forth before I took it apart. And I am pretty sure it is not the cables because when I bought the boat in January it shifted nice and easy before I took the cables out of the boat. I am worried I swapped the cables on accident. How would I know?

[polariskid23]

It was finally warm enough to pull it out into the driveway and give it a try.

http://www.youtube.com/watch?v=WCTOrqZROI4

[polariskid23]

Has anyone got any advice on how to properly adjust the throttle and shifting cables? My motor is in neutral but I cannot get the controls to work properly. It will go into forward on the controls and then the controls will not go back into neutral. Also it is not shifting to motor into gear. Puzzled.

[mn808gade]

sounds like switched cables. raise the fast idle lever and look at the motor end.