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1959 Mercury Mark 35a - Replacement Starter Solution

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Boatsnhoes

Contributing Member
Had a breakthrough with my motor today. I've been having a lot of starter trouble, went through two original starters and was having issues with low power, overheating, and not working at all. I wanted to document the fix so others can benefit from this workaround.

I replaced the starter with this motor: https://www.dbelectrical.com/products/starter-mercury-outboard-marine-30-35-40-45-50-hp.html

And replaced the gear on that motor with this: https://www.amazon.com/gp/product/B01IFTINVU/ref=ppx_yo_dt_b_asin_title_o04_s00?ie=UTF8&psc=1

All in all an $80 fix to have a brand new, reliable starter. Very happy about this.

Next up is figuring out cooling so I can run the motor longer than a minute or so. Will probably need to drill a hole up top because the normal cooling pathway is blocked.
 
What do you mean by ----" normal cooling pathway is blocked " here ?------Are you talking the tell tale is blocked or something else ?
 
Run a small drill 1/8" into the tell tale at least 1/2" in by hand to clean it out, it's located on the portside of the driveshaft housing, water also comes out of the exhaust relief port which helps determine if it's circulating
 
Not sure I understand...you’re saying there’s no need to restore a tell tale? I suppose that’s true but I’d like to have some way of confirming impeller function when on the water.
 
Quicksilver said:
Run a small drill 1/8" into the tell tale at least 1/2" in by hand to clean it out, it's located on the portside of the driveshaft housing, water also comes out of the exhaust relief port which helps determine if it's circulating
Click to expand...

ive already cleared that part of the tell tale, the obstruction is somewhere deeper where I can’t get to it. I’m at a loss for clearing it, I’ve tried a lot of stuff. Basically out of options so I figured installing the second tell tale on top was the way to go. Can always plug it back up if the original tell tale starts working again.
 
The existing tell tale is at the bottom of the block where the cooling water exits after it has done its cooling racerone is just saying that the motor will still be cooled even with a plugged hole. I can't find the thread where you mention drilling a new hole.
 
Quicksilver said:
The existing tell tale is at the bottom of the block where the cooling water exits after it has done its cooling racerone is just saying that the motor will still be cooled even with a plugged hole. I can't find the thread where you mention drilling a new hole.
Click to expand...

I see. Yeah I just want to have the assurance that the impeller is working. I think you may be the one that advised me on hole drilling actually. ’m on mobile otherwise I would dig up the old thread but it should be there if you go back in my posts.
 
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