Mercury 6 hp outboard gets a new water pump new gear oil 1966 vintage Merc60 as good as it gets
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- Опубліковано 7 лют 2025
- Today we service the water pump on a 1966 Mercury outboard and change the gear oil with my favorite oil from Amsoil 75w-90 lube. In this video you will get to see how flawlessly this 54 year old outboard still runs.
Thank you for sharing your experience about the shifting problem....I've got the same problem, but, now I know how to fix it...
I owned the exact same motor in 1977. I'm from Sydney Australia. The water pump was like an alarm clock. You could guarantee every twelve months the thing would need to be replaced. Ended up selling the boat an motor few years later. Your video bought back fine old memories. Great work mate.
got to love the older mercury
they are very differently engineered compared to Johnson's for sure.
We’re getting a cargo container with a TON of OMC parts and several outboards from antique Mercury’s to a mercury 90. Two old Johnson 5 hp...love watching your repairs...
oh man wish I was there to help you sort through and have fun with that container. Sounds like a dream shipment.
Water pump for a 66 or 67 mercury 6 hp 2 cycle?
Thanks for the great videos. I have the same motor as your 1973 4hp. Between the two videos I have been able to go through and do the proper maintenance.
Great to hear!
Great video! Good camera shots and great verbal explanations. I'm refurbishing a very challenging salt water run 1966 Merc 200, but have an old Merc 200-110-75-40 Owner's Manual, with a photo on pg 15, showing the shift lever pointing forward (horizontal), toward the bow of the boat (not up). In the photo, there is a decal underneath the lever, on the cowling, showing to tip the lever up slightly for Forward, middle position Neutral, and down slightly to Reverse. This seems to make sense the way the detents and gear shift bracket inside the cowling are set up. Whatever decal used to be there is long gone.
Great Stuff. Thanks for sharing.
What would you take for that 66 motor .
Thanks to your video, I have now replaced the impeller on a 66 Merc 60 I picked up, I replaced the oil in the gearbox and fabricated a new fuel pump diaphragm, I also had to use a larger fuel connector, as I couldn't find the right one, being in the UK doesn't help.
Glad I could help
The small style fuel line connectors got scarce, and NO, Michael, they do not have the check valve like the larger bayonet fitting. Hung me up for a while too.
I can't find one either
I have one of these in my garage. Bought it from the daughter of the original owner, out of his estate. I wanted one of these SOOO bad when I was 10 years old to push my rowboat. My dad said, "Maybe next year..." The next year, I of course wanted something bigger 😏 But I never forgot about the 6 hp. that got away. What good is eBay if you can't finally buy the stuff you wanted when you were a kid? 😄 Even these pre-1970 models that still have points and condensers run like sewing machines. With 7.2 cu. in. and twin cyl's, they're almost miniature.
The decal for the shift lever is still on mine. "Up" is forward, "down" is reverse and level (horizontal) is neutral. I have a '69 9.8hp, it's the exact same. I believe they changed in '71, when they put the stop button on the side, forward of the shift lever, so they had to reorient it to get it out of the way.
I just picked up a 1960 5.9 thanks for the instrs
You are welcome, thanks for watching
Loving your videos while I am doing an impeller change on my 1972 Merc 40 4 HP long shaft. All of the videos I have watched show the flywheel rotation to be clockwise. My hood mounted pull starter rotates mine counter-clockwise and that's the way it runs. Impeller vanes face opposite of what the other videos show. Do you remember anything about this? Merc made many year to year changes in this era, including the direction you move the shift lever to go forward. I'm in the middle of an impeller replacement on mine. I'm in Minnesota. C'mon up, we have some extra lakes! These old Mercs really bring back memories. I was 16 in 1972 and was in a Boston Whaler with a 20 HP Merc.
The old mercs are some interesting engineering for sure, thanks for watching
Mine has a front facing shifter. Yours is pointing up. When facing front, up is forward, down is reverse, front center is neutral. This is why I believe you had what appears to be a "reversed" setup. It is the orientation of your shift handle. Great videos and cool personality. Good job!
Thanks for sharing and thanks for watching
Enjoy the videos, my good man. thank you.
Glad you like them!
My grandad had a Merc1968 9.8, and a 1975 4.5. They ran nice but the drive shafts would rust, and take out the seal on the water pumps, Then oil or gas would get in and swell the impeller and it would break free from the brass drive sleeve. I brought the driveshafts to a shop and had them hard chromed, and never had a problem again. I still have his old 4.5, and his 35 horse, Johnson golden javelin.
That’s a great fix for sure
I greatly appreciate this video it helped a lot thank you very much!!
Glad it helped. Thanks for watching
Nice motor, good job!. On my Dad's 6hp Merc. , I seem to recall the shift handle pointed straight towards the bow when in neutral. We would push down for forward and up for reverse. I remember replacing the handle on my father's 6hp. I believe it was a friction fit with a pin??. I'm not sure though because it was 30 years ago.... If you can remove the handle and put it back on pointing down when in neutral I believe that's the correct orientation.
You would be absolutely right. pointing it down makes sense. Then pulling it forward for forward and pushing it back for back would work and make perfect sense. It would be a odd duck, all other outboards the handle is up.
A real sweetheart Merc
I just bought one today, it appears to be same model. We will see if mine is as sweet, either way, the price was right!
hope it works out for you.
The shift handle on a Mercury is designed to be in a horizontal position when the motor is in neutral, click it up for forward and down for reverse. Johnson/Evinrude the handle is in the upright position, so you pull it forward for forward, and backward for reverse. I noticed your handle was installed in the upright position like a Johnson. If you loosen the screw and rotate the handle to the proper position, it works and looks as it should.
Sounds about right.
The splined shift shaft needs to be checked and oriented before reassembling gearcase into mid-casting. Yes, the shift lever will be horizontal for Neutral, but the splined shift shaft will spin round and round. Need to work the prop shaft against the lower ratchet mechanism both ways to determine proper lineup
My father just picked up yesterday that identical motor, we haven't done anything yet but seller said it'll need the water pump kit.. THANK YOU SO MUCH! (Do you have part numbers for that kit)
Great job
Thank you
@@Michaelsbackyardmarina I have a 9.8 1969 the shifter lever works the same as the one on your 6.0 mercury
Thanks for the video! I just scored a 1964 6 hp that my neighbor gave me. I was surprised you didn't apply grease to the bearing. Try banging on your camera when it goes out of focus.
Great tip!
@Brian Jayce Did you bust her doing anything crazy?
Instructive video. Part numbers of the parts you installed would be helpful.
Yes please
Is part 2 out yet? I have a basket case 67 20 hp I gotta put together. I really enjoy your videos. They are extremely helpful. Thanks!
I can't get my dang cover back on how did you do yours so easy!?!?
Carl would be Proud
Sweet little engine there
thanks
Awesome 😎 video.
Glad you liked it!
Great video, I'm waist deep in a project to rebuild 3 old mercury outboards, where do you get your parts pls? Also, where is the serial number on the old rigs? Thanks!
I need the same information please
The shifter was in the correct position when you started. Pointing up is forward, towards the front of the boat is neutral, and down is reverse. Hope you didn't screw it up
Thanks for the tip. Nope didn't mess it up.
Hi Michael,
Been folliowing you for a while, same like you I have them stacked like furewoid here, mostly runners. Got a 1964 9.8hp Merc that is a Super-Sweety and having trouble keeping gearcase sealed. Its a twin for your 6hp Merc, I could go on cuz I'm a lifetime fanboy for Mercs (62 y.o.), but anyway, my shift shaft is corroded and having trouble finding another, NOS or otherwise. Looking into a Seal Saver sleeve if they are made that small. Or possibly braze and re-machine that surface where the seal contacts the shift shaft.
Yes, the shift lever is intuitively backwards, but that's how that series runs. I've seen the double-reverse or otherwise on many Mercs, it's just a matter of aligning the blind spline properly as you did.
good information. Thanks for watching and commenting
That would go lovely next to my thunderbolt 850, shipping to CA must be ridiculously pricey though. Been searching for a good kicker.
shipping would be quite pricey.
Rmd you are a maestro of boat motors. I have an old evinrude that has been on my bench to get running for a while. If I could send it to you, I'd give you 2 more boat motors to get my Evinrude running. I don't do Facebook or anything but you can text me at 937-207-7020 and I'll send you some pictures. It's going to be a challenge for you. Thanks for the videos. Richard Ludwig
@RMDCreations - First off...THANK YOU for this video. I am trying to help my sons friend on a 1968 200 20 HP. Needs an impeller. I only ordered the impeller at this point so hope I don't need all the parts you ordered. The shifter thing had me for a loop as well, it is really STIFF on shifting so i will have to look at it when we drop the boot. When you put the boot back in, did you have it in neutral or in forward? Also did you have that gear spline with the missing spline like you had in the video pointed back? Also for the lower gear lube, how much (Capacity do you need?)/ Again thank you for the reference video!
I had it in forward, I think all the small mercs have the missing spline, It takes not even 1/2 a quart, thanks for watching
I am now working on the exact same motor. There are a few issues that I've been able to take care of, but I'm not sure whether the motor is pumping water all the way through. I believe it should be coming out at the exhaust area just below the lower cowling at the rear. Should it look like a typical tell tale stream or does the exhaust kind of atomize it? Thanks
I just took in what appears to be the exact motor for repair. Please let me know where to buy the necessary parts! Thanks in advance. Great video, by the way!
Marineengine.com or Oldmercs.com
I just drove 9 hours round trip for a 1968 long shaft to use as a kicker motor on my 1995 Alumacraft. I took the Fiat to save on gas. 😂 A nice motor. I am excited to try it out. Where do you find the replacement parts for these?
MarineEngine.com or oldmercs.com
Michael I need to know what the model number is on this motor. I have this exact motor. I guess I need it to order part's. I can't find the model number or the serial number on my motor. I need to order a female end on the fuel line so I can try to start it. Apparently they come in different diameters. The one I bought was to big. I can't find the right size. Thanks for your help
On my 67, put the trans switch back for forward, middle for neutral, and forward for reverse.
Great video. Where is the drain/fill screw-plug to change the lower unit oil?
there are plenty of videos showing where it is located. I have several gear oil changing videos. do a quick search
You should use more grease, it will extend the life of those seals and o rings. Use saltwater proof grease. Also apply it to the shafts as well.
I just did this with my MERC 60 6hp... No water is spitting out the top like your video shows... Everything is put together properly, is there a thermostat??? Or could the water ports be clogged? Thank you for your time!
Do you have the part number or even better a link to the kit for this? I have an identical outboard that's supposedly a 69 and am having trouble finding one for it.
Do you happen to know how I can get ahold of the fuel connector for this motor?! I have a ‘66 and I cannot find the correct size. I’ve bought three connectors that are all too big! Do you have a part number or anything? Any help would be much appreciated!!
oldmercs.com
@@MichaelsbackyardmarinaThanks I've been trying to find one myself. You make great videos. Thanks for all your help
Thanks RMD, question: Do I have to drain gear oil before removing lower end? I changed gear oil and impeller and still no water, now I just want to open it up again to see if I did anything wrong without draining the gear oil.
you don't have to drain the gear oil.
@@Michaelsbackyardmarina Thanks again RMD
Great work and videos would like to see you do a complete restoration on one sometime thank you!! I just bought the same exact outboard 2weeks ago 1966-1968 Merc 60 6hp rebuilt carb now waiting on water impeller kit !
17.20 Isn't it an easy way to refill new oil at the same time when you've removed the seal to the gearbox. Then you are 100% sure that you filled it up?
Bud, you really made my day with this video! I’m into the very same job and wasn’t going to bother with pulling out the lower casing for the water pump. I didn’t even realize there was an o-ring and seal down there. Parts ordered!? Any trick to taking that lower seal out? I’m cursing a bit. Going to dip the whole apparatus in boiling water to see if that will loosen things up. Also, thanks for calling out position of shift shaft. I was wondering about that too!
Great to hear! Are you talking about the drive shaft seal or the output shaft seal?
@@Michaelsbackyardmarina hmmm, I’m referring to the one that is on the underside of the bottom half of the water pump assembly - does that help? Right below the largish o-ring that I think you also replaced.
Where did you add the gear oil
Excellent video congratulations, I won a Mercury MERC 60 Twin 6hp 1964 serial number 1737906. I need the service manual. I bought one that has Mercury from 1940 to 1970 but it is very generic. I will restore the engine and leave it 100% original. I would like your help if possible. I'm in Angra dos Reis Brazil. Congratulations again for the video.
Great job I have 7.5 Mercury serial no 9154804 how old is it,I believe it's in the numbers some where
check out marineengine.com. you should find information there.
@@Michaelsbackyardmarina Thanks will Do.
Where do you order the parts for these older motors
Great video mate. much appreciated! I have the same motor, and want to change the zinc anodes... only problem is I can't find where to attach them! any ideas?
the ones I have seen were attached to the top of the cavitation plate.
@@Michaelsbackyardmarina thanks for the reply mate. I will attach one there
Should get a mini split they work great
could after my current stuff wears out. Thanks for watching.
Just got this motor 1. I can’t find a fuel connector that fits lol 2. What fuel do I put in it is it a mix or just gas 2stroke or 4
You only use outboard 2 stroke oil mixed in a ratio of 50:1 using non alcohol gas.
I just bought a 1962 Merc 110 9.8hp "white" motor for my new dinghy. Looks almost new. Run's great so I'm just putting in a new impeller and changing the seals as I had water in oil. Is the water coming from the shift shaft or drive shaft seals?
You will need to pressure and vaccum test the gearbox to find out which one is the culprit.
@@Michaelsbackyardmarina thanks, forgot about doing that. You said your from Iowa too, I live in Ankeny. What parts are you from?
How can you tell if these are pissing? I can’t find a tell tale on mine
I just picked this motor up today. I need some help on something. Please hit me back
Should watch an old video where mercury ran 50 thousands miles non stop in the late 50's on lake x in florida showing how tuff there made....
I have watched that video, amazing
I very much enjoyed your video as I have the exact same motor that requires the same water pump repair. I have one question though, when you removed the water pump cap assembly and exposed the shaft bearing why did you not put any grease on the bearing or it doesn't require it? Thank you for your response, Lou
It runs in gear oil. When properly filled it will have all the lube it needs.
I have a 71 7.5 hp red letter and looking for the hose to see where the water should pump.out and can't find out where it comes from
keep watching videos and you will locate a video that shows where it should be. Thanks for watching
Could you post a link to the female fuel line connector that connects to the engine? I have a Merc 60 exactly like yours, but I need the fuel line connector. Thanks
I need one also
What foot oil does the motor need I just got the motor yesterday and I am stumped right now
I use Amsoil 75W-90 outboard gear oil myself.
When you install the foot back on, do you have the shift shaft on the foot all the way up or pushed down. I just finished putting the new impeller kit on and everything was good including the missing spline facing the main shaft, the shift lever in the forward position but it just stays in gear when I fire it up and I'm getting really discouraged
Not sure what you got going on there. Could be a worn part in the gearbox.
This same thing happened to me and I don’t know how to fix it.
Would u like to video my 1929 Johnson otb it is complete and was running 7 years ago....made in S Bend IN.....all bronze, brass and Alum. runs off magnito and is rope start.
If you are asking if I would like to work on your outboard the answer is no. I don't work on other folks outboards. I make it a practice to just work on my own stuff. Parts sometimes takes a long time to get and people tend to get upset with me because of parts availability. I just avoid that drama by saying no.
Where do u normally get parts from and how do u look up correct parts?
MarineEngine.com or oldmercs.com
I thought my guide tube was missing when I took mine apart turns out it was jammed up inside the upper unit 🙃
Glad this helped. Thanks for watching and commenting.
@@Michaelsbackyardmarina I keep getting water in the lower unit tho any idea on what part it could be? Obviously coming from prop area I think?
Hello, do you know the displacement (ci) for an 6hp twin merc 60 ?
Thank you
no idea, thanks for watching
I just bought a 1966 6 hp merc, and the reverse lockdown release linkage sits way over to one side of the locking mechanism, there for it pulls it cockeyed and only releases on side, Is it possible to get you to post a picture of what it is supposed to look like, Thanks
I don't have one just yet to get the picture of.
That little rubber ring on top of the pump is a water flinger.
Yes it is
Is my 1968 110 9.8hp gonna be reverse thread to remove the prop nut?
I have a 1964 6hp Merc. Where did you get your parts? Thanks.
How much can one expect to pay for a decent running old Merc 60. I'm going to follow ur vid & fix one up. I need that shift lever. Mines broke off. Did you know where to get a part like this. And I need the fuel hose. Did you find one? Seems like a darn good vid. Thx
Ok a price for one that needs no work like one I would sell when I'm done working on it would go for between $500-$600. One that needs some TLC you should be able to find for between $200-$300, and you many have to put a couple hundred into it to make it lake worthy.
@@Michaelsbackyardmarina Thx. I appreciate it. I need some parts as mention. You gotta source?
@@MS-oz2wu If it's an old merc go to Old Mercs .com and or marineengine.com
Always good to pick up a parts motor of the same year if you can.
Where do u get your parts
Could you send me the list of parts you ordered fir the water pump rebuild and all associated seals and o-rings please. I have a 1968 6 HP that I need to redo. Thank you.
Any luck getting those numbers? I need them as well.
I have this exact same motor, did the service, impeller, gear oil, I have a question. Does the expelled water come out of the exhaust? Or should I see a pee stream? Thanks
it comes out the exhaust.
I have a 1964 6hp and watched this video as I needed to change the water pump as well. I cannot get my lower unit to go back on. On the first attempt it went on far enough the prop woud turn over the engine, It then became difficult to separate and now wont go as far. I believe my shift shaft is in the position you show. I tried with the gear shift on the housing I think in forward but still no luck. Can you please advise wht I need to do?
it sometimes takes some fanaggaling to get them back together. Patience and you will get there.
HI NEED SOME HELP. i PICKED UP A 1968 6 HP TWIN BOUGHT A NEW NEW FUEL LINE CONNECTOR , BUT IT WILL NOT FIT INTO THE GAS PORT ON THE FRONT OF THE MOTOR. DID MERC MAKE MORE THAN ONE SIZE FUEL CONNECTOR?
Yes they did. check out oldmercs.com
I have a slightly newer 7.5 mercury outboard. When I dropped the lower unit the water tube came down with it and the shift lever stayed with the upper unit. I can’t pull the shift lever loose from the top unit... what could cause that? Also, what holds
the water tube into the upper unit? I can see the hole for the water tube inside the upper unit but the tube is much smaller than the hole. Is there supposed to be a rubber tube similar to the rubber tube on the lower unit?
Johnny I’m looking at a 1960 Mercury 9.8 with the gear change feature in the tiller handle. Looks fairly unused to me. Do these models need pressure gas tanks and what else do you know about this era motor?
most all need a pressure gas tank. Haven't seen one with the shifter on the tiller.
Jaką stosujesz mieszankę do tego silnika 1,,:50 ?
I have a 60’s merc 9.8 i just picked up, do you know where i can get the fuel line fitting on the frontside of the motor to connect it to a tank??
I would check our Marineengine.com or Oldmercs.com
I have noticed whenever you see a brand new boat package they almost always come with Mercury outboards. Are Mercury outboards still good motors?
From what I have seen preference is very regional. In Iowa Mercs seem to be the popular motor. In South Carolina it is Suzuki. I think a lot has to do with what kind of dealer support you have in your area.
I have a 79 mercury 4.5 hp.
Where can I find the plastic choke screen because I just bought it and the choke switch broke on the inside where it connects to the screen.
I have one for you....
@@staffanfogelberg6816 how would I go about getting it?
This gas &oil mix how would you run it?
50:1
@@Michaelsbackyardmarina thanks bro
Where do you get your parts? I have a 74 mercury 7.5hp I am working on.
marineengine.com or oldmercs.com
Where are you ordering parts from
oldmercs.com
Those impellers are not interchangeable. The center hole for the driveshaft is .438 on one and .456 on the other I think.
interesting
@@Michaelsbackyardmarina I had to ream my impeller before it fit on the shaft.
Reverse lever on my 7.5hp is horizontal in neutral position.
Thanks for letting us know and thanks for watching
Just picked up a merc 60 6hp sn#2140694 The guy told me it was a 1994 so I paid $300 then find out it’s probably at 1968 and was upset until I watched your video I think it wasn’t pumping water out like yours was so also I need a parts list if you can provide one
Great video, very helpful! I have the foot taken off and waterpump housing off. There was no key on the impeller! I look further and the keyway on the shaft looks like it is ground down. Quick question, how deep is that keyway? I really hope i dont need to buy a new shaft. The engine was passed down to me from my Grandpa...would love to get it running!
At 20:11 in the video you can see what the key looks like.
where do you get your parts from?
Can I ask where do you find the parts for old outboards? Do they have a exploded parts diagram to help you pick the parts you need?
crowleymarine.com and marineengine.com an yes they have diagrams
Are there any numbers on that lower unit I’m looking for a lower unit for a 69 merc 40 4hp
no numbers that I know of
@@Michaelsbackyardmarina Hi. I have a merc 9.8 hp motor. Not sure of the yesr, but does not matter for this question. Upper oil level hole was stripped. The bolt in it was a robertson 10-24 bolt. The bolt would just spin around and not come out. Stripped obviously and leaking water obviously. The oil was milky. Can I re-tap that hole to a larger size like a 12-24 or a 1/4 inch. Or what do you recommend. I don't want to have to replace the whole lower unit. But I do have to seal the hole. Reply to bcargill@sasktel.net please.
There are small factory #'s stamped inside the enclosure.
does anyone has a source for parts on the 62 ?
www.oldmercs.com
Do you have the PN of the parts/kit? I need to order a rebuild kit with pick up tube
sorry I don't. Check out oldmercs.com You can find your parts there.
What did you use for the fuel line connector ?
Just the standard mercury connector. Got it from oldmercs.com
I watched the video to see where and how you check the lower end oil . there was nothing ecept you said you checked it Bummer
Boa noite preciso do prato de partida manual do Mercury 6hp ano 1968
Thanks for watching and commenting.
Oh god, did you buy a little dirt bike?
nope fixing it for a guy.....video to come.
Help!!!
Hi. I have a 9.8 hp merc. The upper oil fill hole is stripped and leaking water. Can I retap the hole. Previous owner had a 10-24 x 1/4 robertson screw (bolt) in there. I doubt that's the right thing. Recommendations? Bcargill@sasktel.net
thanks for your videos! they are helping me restore a 1968 Merc 6hp 60J that was purchased new by my grandfather. its been sitting in a garage for 25years. unrelated question to this video, but i need to replace a damaged piston and my manual is calling for item 703-3375A4. the only pair i can find online are 703-3375A5. I cant find any information on what the difference is between them. any idea? thanks again!