Mercury Tracker 40 HP 2-Stroke Engine Build | Mercury Tracker 2-Stroke Engine Rebuild | Boats.net

See how to rebuild a Mercury 40 HP 2-stroke engine in this video from Boats.net

For us, this is actually more an engine BUILD than a rebuild. A while back, we took this one apart and discovered a pretty big hole in the engine block. So instead of a rebuild, we’re going to salvage what we can off of the damaged engine and build one up with a new block.

We’ll start by taking apart the crankshaft and piston so that we can check out what we can use and what we have to toss. Once that’s done, we’ll work on cleaning and polishing our crankshaft before we get into assembly.

Then, we'll get into the build: the first step is going to be building up the piston and connector rod and getting them in the engine. Then, we’ll drop in the crankshaft. We’ll round out our Tracker 2-stroke rebuild by bolting on the reed block on the bottom of the engine.

Check out everything we need here:

Connector rod:
https://www.boats.net/product/mercury...

Lock ring:
https://www.boats.net/product/mercury...

Piston assembly:
https://www.boats.net/product/mercury...

Lock ring installer:
https://www.boats.net/product/mercury...

Engine block:
https://www.boats.net/product/mercury...

Connector rod bolt:
https://www.boats.net/product/tohatsu...

Main bearing:
https://www.boats.net/product/mercury...

Top bearing:
https://www.boats.net/product/mercury...

Seal:
https://www.boats.net/product/mercury...

Seal:
https://www.boats.net/product/mercury...

Motion Pro seal puller:
https://www.partzilla.com/product/aft...

VIDEO HIGHLIGHTS:
Introduction - 0:00
Disassembling crankshaft and piston - 2:00
Polishing crankshaft - 6:00
Replacing crankshaft bearings - 10:30
Building up piston and connector rod - 14:00
Installing piston - 22:45
Installing crankshaft - 25:30
Installing end cap and crankcase bottom - 32:00
Installing reed block and intake - 41:45

Find Mercury outboard parts here:
https://www.boats.net/catalog/mercury...

Talk to us:
X (Twitter):   / boatsnet  
Facebook:   / boats.net  
Instagram:   / boatsnet  

In the video we’re working with a Mercury 40 2-stroke outboard, but you may have similar steps for your Mercury outboard. If you’re not sure whether these steps apply to your motor, leave a comment and we’ll get back to you.