Mercury Tracker 40 Powerhead Removal | Mercury 40HP 2-Stroke Powerhead Removal | Boats.net

See how to remove the powerhead from a Mercury Tracker 40 2-stroke in this video from Boats.net!
When we got this motor, we knew there were a few things wrong with it. In this video, we’ll start investigating what exactly we’re dealing with. A quick look at the spark plugs gives us some clues, but the real story comes through the lens of the borescope. We’ll show you exactly what we saw when we looked inside the cylinders.
With a basic diagnosis, we know we have to get the powerhead off. We’ll show you how to get the Mercury 40 powerhead removed by disconnecting just a few items and then removing a few bolts.
See these diagrams for a closer look at where we’re working::
Driveshaft housing: www.boats.net/catalog/mercury...
Cylinder block diagram: www.boats.net/catalog/mercury...
VIDEO HIGHLIGHTS:
Inspecting the spark plugs - 0:40
Borescope inspection - 1:30
Removing cowling - 3:00
Disconnecting oil reservoir - 3:50
Disconnecting telltale - 5:00
Disconnecting trim relays - 6:25
Disconnecting main bolts - 7:00
Removing the powerhead - 8:00
Find Mercury outboard parts here:
www.boats.net/catalog/mercury...
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In the video we’re working with a 2002 Mercury Tracker 40 2-stroke outboard motor, 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.
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[@samfusco8158]

John Tally is the best! Makes every video easy to understand.

[@rafwhy9888]

great video great website

[@ramseytrain]

had the same problem rod bolt came loose and bearing came out. had it bored and new pistons replaced

[@texasghost-rider]

Love the videos! I have a 1996 tracker 40hp force series. It doesn’t have a tell-tale. Is there a way to have one so I know it’s pumping water?

[@toddhoutz6764]

Logging and you can use swap Mercury with Force with power heads

[@jbkahl]

John what is the 2 cycle oil tank capacity on that motor? Thank you. Changing out my 2 cycle oil and just want to see how much oil I need to purchase Thanks

[@toddhoutz6764]

I have a '96 40 horsepower force motor can you put a 50 horsepower powerhead on that motor

[@ramseytrain]

the oilers on these are crap, i switch to premix