Merc KE-4 gas tank question

[huntleybill]

The threads for the gas tank filler are pretty buggered up. I am speaking of the threads on the gas tank itself and not the cap.
Is there a tap for these threads and what size would that tap be?

Thank you all
Bill

[dave-bernard]

I have one some where.is it the large cap or small one . best way to tell is look at the filter if it is a large hex it is the large cap.

[green-thumbs]

Mercury Service Tool Catalog in Old Iron section of Inner Sanctum give the taps sizes needed
for both large and small gas caps. Two cap threads related to change from small brass in tank
filter to large hex nut black in tank filter.
Louis

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Charles Byron

[huntleybill]

The gas cap spout looks to be about 1 -3/8" outside diameter. I don’t know if that is the big or the small hole.
I can no longer get into the inner sanctum. I emailed support.

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[dave-bernard]

give me a pic of the bottom of the tank the fuel line connecton.

[huntleybill]

Um…ok but I need to repair the threads for the gas cap. Not the fuel line connection.
What does the bottom of the tank tell you?

[billw]

He wants to know what the fuel connection looks like because the big, hex fuel filter went hand in hand with the bigger size fill neck.

Are those bullet holes in the tank? Did somebody do a mercy killing on your engine?

When we all figure out what size tap is needed to fix your threads, we will also need to find a tap that doesn’t exceed the value of the motor. Those big taps, of any quality, are very, very expensive….

Long live American manufacturing!

[chuckw]

Get a tap of the correct size and tap out the hole. I have done that on green tank Mercs.

[huntleybill]

Ahh…ok Bill That makes sense.
And no, those aren’t bullet holes. I attempted to glue some nails to the dented area to pull out the dent. It was a dismal failure so I have to figure something else out.

Here is a picture of the fuel line connection per your request:

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[dave-bernard]

that is the small cap tank.

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