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    Mercury thunderbolt 500

    You can look up the year using the serial number on the maxrules site
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    Rust, generally how to clean and best spray to keep it from rusting?

    Galvanized paint needs to go on bare metal. It works best on metal already galvanized, but needing a touch up. If the trailer is painted, and sandblast is not available, sanding, priming and overcoating is the next best option.
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    2006 40hpELPTO 2 stroke, is some white smoke normal?

    I like to use a tub at the end of the season to give the engine a good flush to get all the salt out.
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    Need help finding controls for Mercury Sterndrive.

    That PTT panel is pretty well made with heavy copper push button contacts. You might check the wiring as that is the weak spot. To tilt the engine up, push both middle and top buttons together. If the trim limit switch on the outdrive is working (most don't work at this age), the middle...
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    Tachometer

    Tachometers run off stator pulses. The yellow wires come from under the flywheel and carry those stator pulses (a form of AV voltage) to the VR. You might put a voltmeter on the battery terminals when the engine is running and charging. Check for AC voltage at the battery. If you see some...
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    Old motors DEMAND to be retired when they are 65 years old..

    Motors only retire when their bits fly out new vents in their crankcases.
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    Tachometer

    Does the engine charge? If so, connect it to one of the yellow wires and be done with it. If not, maybe you need a new voltage regulator.
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    2004 mercury flywheel

    I picked a likely engine model at the crowleymarine web site and looked up your flywheel. They have it fitting 61 different models. However, I am not certain it is the one on your motor, so it needs doublechecking. https://www.crowleymarine.com/mercury/products/8m0053921-flywheel
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    Looking for the right tach harness from controls to tach?

    The tach needs +12VDC, ground and a signal to operate. This power and ground comes from the ign switch. So get out the test light or multimeter and see if she has +12VDC and ground. As for the tach signal, put a multimeter set to AC on the grey wire on the voltage regulator at the motor...
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    2006 40hpELPTO 2 stroke, is some white smoke normal?

    Hang the thermostat in a pan of water on the stove. Stick a thermometer in the water as well. Heat the water and observe the 'stat. It should open at about 140F Or just replace it.....
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    4.3 spark arrestor replacements

    A 2 bbl 4.3 engine usually produces about 170HP. The 4 bbl 4.3LX produces 205HP. Are there any other differences between the 4.3 and 4.3LX other than carb and intake manifold?
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    Rust, generally how to clean and best spray to keep it from rusting?

    I like the Rustolium rusty metal primer or the Rustolium clean metal primer. These need to be covered with a topcoat of paint, as they are rather soft.
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    Changing 4 stroke motor oil

    Marine engines operate under more load than automobiles. They therefore require oils that do not thin out as much as automotive oils. The spec for marine engine oil is FCW (Four Cycle Water cooled). I would stick with the proper oil.
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    2006 40hpELPTO 2 stroke, is some white smoke normal?

    White smoke is usually steam. On a cold day, some is to be expected out the exhaust. You should not see much/any on a warm day. The temp of the engine is controlled by the thermostat. If it fails, the engine could start to overheat, causing steam even on a warm day. Thermostats do not last...
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    4.3 spark arrestor replacements

    Gee, my spark arrestor was a lot more than a screen. It was a stack of aluminum plates, riveted together. I cleaned it every year.
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    Rust, generally how to clean and best spray to keep it from rusting?

    Only use "cold galvanize" paint if the area to be painted is galvanized steel. if it is painted steel, the rust is best removed, the area primed with a good rust resistant primer and a top coat of paint applied.
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    4.3 spark arrestor replacements

    It should be cleaned every off season. As it is all metal, most any solvent is fine. I often hosed it off after the solvent cleaned off the dirt.
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    to vent or not to vent, that is the shrink wrap question

    Generally, you want ventilation. It is very hard to keep water and moisture out, so letting it dry is essential. I cover my boats with a simple ridge pole and tarp. I leave the rear open around the outboard motor hood to allow ventilation. In the spring, mildew is usually pretty light as...
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    1988 Merc 115 inline 6-Rough in low gear only after WOT

    Tough one...check for exhaust leak under cowling, or simply run it with wrap cowling off.
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    What type sterndrive

    Check the u-joint yoke that the oil seal rides on. Often these get grooved and will ruin a new seal in a short time. The fix is to replace.
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