1972 Mercruiser 120 quit

SS Maniac

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Long time lurker, first time poster. Folks here have helped me through several issues, thank you. I read a post that would've helped me out this morning, and I'll be switched if I can find it again, so I finally signed up.

I have a 1972 Starcraft SS 18 with a 120hp MerCruiser 120, love the boat and was dealt with great sadness yesterday. I had to be towed in. :(

Here's what happened, I towed the wife and kids around in a tube for about an hour, all went well. Dropped them off on a beach and went for a spin around the lake. On my way back to the beach, engine slowed and eventually died. When I turned the key, it clicked, as other have stated it was a clunk more than a click, so much so that it'd move the steering wheel. It would not turn over. After floating about, and occasionally clicking/clunking, the motor did turn over, started and I was off. I slowed as I got closer to the beach, it died and same series of events ensued.

Here's what I'll do this week:
1. Pull plugs check for water (oil was crystal clear, so no water in their).
2. Try to turn over w/o plugs
3. Pull starter and try to turn motor by hand
4. Perform compression test
4. Worse case, pull lower unit, see if it frees up

Few questions: How do I test the solenoid? Any way to repair gears if they are bound? If motor is bad, any installation suggestion for putting a 4.3L in place of the 120, specifically anybody build motor mounts for an aluminum hull?

Final note, the puzzling part of the starting process, to me, is the boat has to be in neutral, what the heck?
 

Scott Danforth

Grumpy Vintage Moderator still playing with boats
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if the motor slowed then died, pull the drive first.

how does the gear oil look

boats have to be in neutral when you start it so you dont run people over.
 

Bondo

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Here's what I'll do this week:
1. Pull plugs check for water (oil was crystal clear, so no water in their).
2. Try to turn over w/o plugs
3. Pull starter and try to turn motor by hand
4. Perform compression test
4. Worse case, pull lower unit, see if it frees up

Ayuh,..... Welcome Aboard,..... The 1st 2 things I'd do is,....

Pull the spark plugs, 'n drop the oil outa the drive,.....

Yer lookin' for water in the cylinders, or metal in the drive oil,.....

Ya test a solenoid with a test light to see where, 'n when each terminal has power,.....
 

SS Maniac

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Jul 29, 2019
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Scott, my apologies. I knew it had to be in neutral to start. Question is, if in neutral and safety switch pulled out, in my pea brain, seems like it would turnover if it’s not an engine problem. Right or wrong?

p.s. to projects ahead of boat, won’t likely get to it til Thursday. Feedback so far, appreciated.
 

SS Maniac

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Alright, moved this up with respect to project order in an effort to get parts and install complete while family is out of town. First, sorry for the misspelling I'll be danged if I don't know "to" above should be spelled two.

Removed the lower unit tonight, motor started right up, thanks for the advice. New questions:

1. Top bearing was disintegrated!
2. How do I go about getting race off shaft?
3. How do I get race out of cap?
4. On parts website "shims" are needed, how do I ensure I get this right?
5. Noted rust on u-joints and water in "boot", is this a problem? Suggested remedy?

Everything else seems straight forward, replies appreciated.
 

Grub54891

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Jun 17, 2012
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6,305
Much faster and easier to get a new drive. If the shimming is not correct, it will blow again. Special tools are required to set them up.
Water in the boot means there is a leak in it. Many time for a bellows job.
 

Scott Danforth

Grumpy Vintage Moderator still playing with boats
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Jul 23, 2011
Messages
51,375
Alright, moved this up with respect to project order in an effort to get parts and install complete while family is out of town. First, sorry for the misspelling I'll be danged if I don't know "to" above should be spelled two.

Removed the lower unit tonight, motor started right up, thanks for the advice. New questions:

1. Top bearing was disintegrated!

and all the parts went with the oil and trashed the lower. buy a new SEI drive with a 3 year warranty.
 

SS Maniac

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Thank you, not opposed to buying new. Searched yesterday and there appears to be several options. Which do I need for a 1972 mercruiser 120 stern drive?
 
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