Mercury Tracker 40 2-Stroke Powerhead Teardown
After removing the powerhead from our Mercury Tracker 40HP two-stroke outboard engine, it’s time to tear it down completely.
We removed the powerhead from our Mercury outboard and tore it down because the engine was sounding bad, and upon further inspection, we knew there was serious trouble and that it might be beyond saving. Some broken metal pieces were found in the base of the cowling. One of the connecting rods was also visible from outside the engine, which is catastrophic for the crankcase.
Watch the video above or follow the steps below to tear down the powerhead of a Mercury Tracker 40 two-stroke outboard. Use our cylinder block and crankshaft and flywheel parts diagrams for additional reference.
Special Tools Needed - Mercury 40 Powerhead Teardown
Mercury Tracker 40 Powerhead Teardown
Step 1. Remove the linkage arm and the carburetor.
Step 2. Remove all connecting lines.
PRO TIP: Take pictures as you’re removing all of these parts, and use our exploded parts diagrams for additional reference.
Step 3. Remove the intake.
Watch the clip below to see the intake and carburetor removal segments of our Mercury Tracker 40 powerhead teardown video.
NOTE: After removing the intake and carburetor, we determined the crankshaft is still usable, so we proceeded with the teardown.
Step 5. Remove the starter motor, and all electronic parts and wiring.
Watch the clip below to see the electronics removal segment of our Mercury Tracker 40 powerhead teardown video.
Step 6. Remove the flywheel using a flywheel puller with an adapter that goes in the center to avoid damaging the crankshaft.
Watch the clip below to see the flywheel removal segment of our Mercury Tracker 40 powerhead teardown video.
Step 7. Split the crankcase halves.
Watch the clip below to see the crankcase splitting segment of our Mercury Tracker 40 powerhead teardown video.
Step 8. Remove the crankshaft.
Watch the clip below to see the crankshaft removal segment of our Mercury Tracker 40 powerhead teardown video.
Step 9. Remove the pistons.
Watch the clip below to see the piston removal segment of our Mercury Tracker 40 powerhead teardown video.
With the Mercury 40 Tracker’s powerhead stripped, it’s time to order parts and rebuild it. Stay tuned to our blog for the next installment of our Mercury two-stroke outboard powerhead rebuild.
