1982 Mercury 40hp Outboard Part 2

[@erandam2011]

Please do a detailed video on this motor with anything you do on it. So far you are the only video of the 82 40hp mercury outboard. I have the same one on a bass tracker that i dont know much about and already your video has showed me great information on it. Thank you.

[@TheAfterWorkGarage]

Glad it helps! I still have part 3 coming, and I'll post anything else I end up doing with the motor.

[@erandam2011]

@@TheAfterWorkGarage Thank you. I definitely will be looking forward to part 3. Was happy to see you had loaded part 2. Nice knowledgeable work and info. Greatly appreciated.

[@brandonbeene7813]

@@erandam2011 is yours 50:1 or regular gas? I have the same motor and the guy I purchased it from says it’s 4 stroke but there is no where to put the oil.

[@samir_wf]

Great video! Thanks for posting it. I've been trying to get the same model to run after sitting for 6 years and it's been tough. The main issues were the carburetor and fuel pump. Now it's firing up but I'm having issues on properly timing its idle and so. Thanks again, I'm looking forward to the next part.

[@TheAfterWorkGarage]

Thanks, I just got the parts in for the poppet valve and thermostat (both of which were seized shut) as well as a new fuel pump. I hope to have some time to get it running and the next part out soon. Best of luck with your motor as well.

[@grimakastatik]

Awesome work. I have an 89 I need to maintain

[@TheAfterWorkGarage]

Thanks, good luck with your motor!

[@goliasyouenn3388]

Hello, do you have the reference of the water pump for this engine, I have the same engine but I cannot find the water pump. Thanks

[@brucemeyer9100]

Good Video. My impeller had no vanes left. The prior owner said he felt that the water pump was shot. I guess that was an understatement. I couldn't get it back together after a many tries. It would get about an inch from where it was supposed to be and stop. I came back here to see if you had any tricks to get it all the way in. I saw and read about ensuring it was in neutral. I am going back and verify the motor is in neutral and the reverse lock is in neutral and the piece on the spline is also oriented as you had it. Would that prevent it from going back together? Thank you for teaching us.

[@TheAfterWorkGarage]

The other thing you might check is the water standpipe that goes from the lower unit up to the leg. It has to mate up to a hole in the block (it's tapered, but you still need to get it close). This tube can flop around a bit and make it a little difficult. of course you also have to make sure the drive shaft splines are mating up, so if they don't mate up a first, a little turn of the flywheel might do the trick (a helper is useful with this if you have someone). Finally, I'm not super familiar with these motors, but there seems to be an exhaust shroud that goes down the leg, make sure that isn't binding up on anything either. It's a lot to line up, and kind of a pain.

[@brucemeyer9100]

@@TheAfterWorkGarage Good suggestions. The standpipe had fallen out and will check to make sure it is seated correctly. I will also take the cowling and spark plugs out as well to allow turning of the flywheel. Plus a dab of grease on the drive shaft. I am also using a rachet strap as a third set of hands to hold it up. Thanks again

[@erandam2011]

Also can you put the part number for impeller replacement parts?

[@TheAfterWorkGarage]

Carburetor Rebuild Kit - Part no. 1395-5109-1 Water Pump Rebuild Kit - Part no. 46-77177A3

[@ruffe7655]

i have the same engine but with the rope pull starter, i want to converse it to a electric starting engine. What parts do i need because im unsure, do i only need the starter engine or a new flywheel with it?

[@TheAfterWorkGarage]

If the block has the attachment point for a starter motor, then it would probably be a matter of just a flywheel and starter, but I'm not super familiar with these motors (if you can't tell lol).

[@YLK-Music]

ive got the same engine, seems like you have an aftermarket fuel filter? how does your fuel line run? is it from fuel tank to fuel filter, then to bottom of fuel pump? then the top of fuel pump goes straight to carby?

[@TheAfterWorkGarage]

I had no idea it was aftermarket! (I'm definitely not a merc expert). Let me take a look and I'll get back to you.

[@thedingerslinger]

Awsome video...Thanks....Getting two of those in a month's time for a steal...To kill it I would disconnect the fuel line quick coupler so that the carbs runs empty as well...Keeps the carbs clean and a easyer start next time....

[@TheAfterWorkGarage]

Good suggestion. As you could tell, I didn't have too much trouble killing it as it was, but disconnecting the fuel is a good way to empty out a carb before working on it or long term storage. Thanks!

[@pyroticpyro1832]

Hey I'm having such a hard time finding part's for my 1980 mercury 2-s 40hp.can u give me any tips we're I can find parts .thx for your time

[@harrybell9143]

What was the exact impeller kit you got for this motor, I’m trying to fix the same motor

[@philipstauffer9092]

Any idea what makes the 40 hp and 35 hp engine different? They look exactly the same and have the same carb rebuild kit? Asking in case i can convert my 35 to a 40

[@TheAfterWorkGarage]

I honestly don't know. Sometimes it's a carb thing, sometimes it's actually something more substantial (like different piston/crank). If I find out I'll circle back and let you know.

[@philipstauffer9092]

@@TheAfterWorkGarage i looked into it and found out that theyre not overlapping years like i thought. So my 35 seems to be the biggest in its class; maybe a smaller (ie 25 hp) could be upgraded to the 35 though

[@TheAfterWorkGarage]

@@philipstauffer9092 That's great info, thanks for sharing!

[@alexandrevenne6721]

I have a quick question for you I have been looking at all your videos I have an issue with my mercury 80 force 1982 Two-stroke the engine runs fine out of water and in water but when I put it in gear and bogs out and stall is it just an adjustment? I have redone the carbs and all the gas lines the spark plugs on you and all four coil packs put out enough power

[@TheAfterWorkGarage]

Hi Alexandre, sorry for the late reply! Hard to say exactly, but if it's otherwise running well, the first thing I'd look at is the idle adjustment to make sure it's idling at a high enough speed to keep running when you put it in gear. I'd also just check to make sure the carb is adjusted well so that it's getting enough fuel, and then look at your compression numbers to see if the engine may just have a general severe loss of power. Is it hard to start?

[@Lukkmaestro]

Does it matter if the lower unit is in gear or neutral when you put it back onto the leg after for example installing new impeller?

[@TheAfterWorkGarage]

As long as the shifter is also in the neutral position it should be fine. Basically you just want to match up whatever the shift selector position is with the lower unit gear position. I find this easiest to do when it's all the way to one side (either forward or reverse), but if you line up neutral, that works too.

[@Lukkmaestro]

@@TheAfterWorkGarage thanks for replying, when i put it back together the propeller "has compression" both clockwise and counterclockwise when the shifter is in forward and when its in reverse it has "compression" in one direction. Is that correct? Havent started it yet

[@TheAfterWorkGarage]

@@Lukkmaestro Turn the flywheel clockwise (i believe) when it's in forward/reverse, and see if the propeller spins the correct direction. That's how you'll know if the splines are lined up correctly

[@ΗΛΙΑΣΑΡΜΑΤΑΣ]

Hello!! I just bought the 40HP same line engine. I m in Greece . The Mercury agent in our country told me though that I cannot find most basic spare parts. Do you have any idea where I can ask for spare parts? Thanks . Elias

[@GhostxDreams]

nice video young man I like the fact that you did trial and error type stuff which shows what can happen and did happen a lot of do it ur self-videos never show the whoopsie parts, but you did and I take my hat off to you i have been working on boat motors for many yrs. and have struggled with a lot of the issue you ran into and like ur-self i also had to learn the hard way of what to do and what not to do you did a great job. of course, there was some stuff that you will have to learn that will make it ezer but thats the learning curve. just one little side note that might be helpfully when putting the impeller into the housing if you will smear a bit of grease any type will do it will keep the rubber from wearing on start up ;) just a tip from one old timer to a young blood lol

[@TheAfterWorkGarage]

Thanks you for the kind words, and the advice!

[@tonywyatt9976]

At 10 mins in what is that drive shaft spline cover called? I keep trying to find a new one and cant

[@dscooper2533]

Did you ever find the part number? I'm looking for the same thing

[@sethgabbard7705]

When running the motor. I saw water leaking out of places it shouldn't. Correct me if I'm wrong. But maybe something is leaking?

[@TheAfterWorkGarage]

I noticed that too, I'll see if it gets better when I track down the cooling system issue. I'm thinking if there's a lot of pressure backed up it could just be leaking out around the standpipe, or the exhaust/water outlet

[@murrayboyle4357]

@@TheAfterWorkGarage I have 2 of these motors but earlier models. Lower water pump section has a gallery port through to the side. Some models have a flushing plug right here. It looks like you have left the o'ring out from between the pump and the housing. You may not get enough water to the powerhead from the leakage.

[@TheAfterWorkGarage]

@@murrayboyle4357 Thanks for the great info, I'll definitely go back and check this before I get it back together and running!

[@thesleep6408]

Having a problem with this exact motor. I dropped the lower unit to change the impeller out. I got it back together and it doesn't want to go in reverse now and when in neutral the propeller spins. What do you think it could be? The reverse lockout? I pulled the unit off in neutral and I hear its supposed to be in forward.

[@TheAfterWorkGarage]

It definitely sounds like either the shifter arm on the upper part, or the splined shaft on the lower unit moved while you had the two apart so when you got it back together the splines are off. I would take the lower unit back off, and make sure that the shifter is in neutral, and then use pliers to turn the splined shaft on the lower unit until the lower unit is in neutral, and then put the assembly back together. It can be a little tedious, but it's not a bit problem. You just have to get it lined up right. Good luck!

[@thesleep6408]

@@TheAfterWorkGarage you were right. Hey I got a question, how do you do a oil change on this motor? Not the lower unit but, the actual powerhead/case oil? I can't find much info on the motor. Maybe even point me in the direction where to get the info. Thanks man.

[@TheAfterWorkGarage]

@@thesleep6408 Hey! this motor is a 2-stroke so it doesn't have an oil sump in the powerhead (motor). Just make sure you mix in marine 2-stroke oil in with your gas at a ratio of about 50:1 when you run it. In short, there is no engine oil to change. The bearings get lubricated by oil that is mixed in with the gas that flows through the crankcase on it's way to the cylinder.

[@thesleep6408]

@@TheAfterWorkGarage hey thanks man. I'm not keen on outboard motors. I work on all our dirt bikes and the bikes have an oil sump so I was just tripping out on where the heck it could be on this motor. I really appreciate the videos and the responses greatly. I'll be watching for that video on when you put that back together. You are a good human and that is rare in this world today. I wish you all the best and god bless brother.

[@TheAfterWorkGarage]

@@thesleep6408 Thank you for the kind words. The same goes for you!

[@joshreef9999]

i have a almost identical motor but the 40 hp. I just tore the fuel pump apart changed all that, cleaned my carb. im having a idle issue. wants to die if just idling. cant start unless i crank the throttle all the way up. would love to see a video on how to properly adjust this. ive tried adjusting the air/fuel and no better. its only at idle, if its 2.5 on tac seems to be fine. makes it very hard to drive bc you have to rev it up then catch it just right to put it in gear.

[@TheAfterWorkGarage]

I'm hoping to get back to making videos in the next few months. I moved, and now live in a different city than my tools and shop. I'll keep you posted!

[@austinbrock5127]

What website or company did order your fuel parts from I need the adapter that locks onto the fuel line

[@TheAfterWorkGarage]

With regards to the fuel fitting, I actually purchased a used/salvaged one off of Ebay. There are some new old stock and new cast metal versions available online, but they are rather expensive, running $50-$80, so I took a chance on an ebay find. Attwood also makes a plastic version of this fitting (amazon link below), but it has a 90 degree connector which might need replacing to fit your motor. I can't speak for this one in particular, but it looks like it may work. Hope this helps. www.amazon.com/attwood-8899LP6-Mercury-Tank-Fitting/dp/B003E21PKU/ref=asc_df_B003E21PKU/?tag=hyprod-20&linkCode=df0&hvadid=343251581167&hvpos=&hvnetw=g&hvrand=6932007682268698998&hvpone=&hvptwo=&hvqmt=&hvdev=c&hvdvcmdl=&hvlocint=&hvlocphy=9026827&hvtargid=pla-744407122975&psc=1&tag=&ref=&adgrpid=69473715299&hvpone=&hvptwo=&hvadid=343251581167&hvpos=&hvnetw=g&hvrand=6932007682268698998&hvqmt=&hvdev=c&hvdvcmdl=&hvlocint=&hvlocphy=9026827&hvtargid=pla-744407122975

[@austinbrock5127]

@@TheAfterWorkGarage do you remember what fuel to oil ratio you ran when starting it?

[@TheAfterWorkGarage]

@@austinbrock5127 I believe I used about a 1:30 since it hadn't been started in who knows how long, but for regular use, 1:50 is usually a good go to ratio unless your motor says otherwise.

[@thomaslindroos1667]

How many turns did you end up turning the mixture screw on the carb?

[@eustolioesquivel9327]

Would u happen know how the gaskets go on the fuel pump

[@TheAfterWorkGarage]

Hi! I actually just got a new fuel pump in for this motor, and I will be filming fuel pump replacement in part 3 of this motor. As soon as I get that video up, I'll post a link.

[@brandonbeene7813]

Was that 50:1 gas and oil or was it straight gas?

[@TheAfterWorkGarage]

That was about 25:1 or 30:1 no ethanol gas and 2 stroke oil since it hadn't been run in a while. I would probably normally run it on about 50:1 or so.

[@elijahparos5198]

I seem to be missing that plastic piece that holds the shift rod linkage in place which makes it almost impossible to get the lower unit back on. Do you happen to know the part number for it?

[@tonywyatt9976]

I’m needing to know that too

[@johnpisaneschi8536]

im not getting power to the gears. and ideas?

[@TheAfterWorkGarage]

Hard to say without more info, but it sounds like it may be a gear selector linkage problem. I'd pull the lower unit and see if things turn properly by hand when you turn the gear selector with a pair of pliers. If it doesn't go into gear that way, you may have a lower unit issue that would require disassembly. Good luck, and I'd love to know what the problem was once you get it worked out!

[@daleacker6214]

Do you happen to have the part names/numbers to the 2 small spline pieces that go on the top of the drive shaft at around 10 min or so in the video. I have looked even where you suggested to and can not find them anywhere. I am redoing an identical motor that I inherited and let me tell you your videos have been awesome and a life saver I really appreciate you and your work!!!!

[@TheAfterWorkGarage]

Hi! I'm so sorry I missed your comment! I believe the parts you are looking for are #32 and #33 in the following parts diagram (www.marineengine.com/parts/mercury-outboard-parts/40-2-cyl/7144763-up-can/gear-housing-driveshaft) Which it looks like can be found at the following: #32 - www.marineengine.com/newparts/part_details.php?pnum=MER88868A+1 #33 - www.marineengine.com/newparts/part_details.php?pnum=MER86304 There also appears to be an O ring in there as well if you need that too! Hope this helps!

[@scottmolis4267]

A little Vaseline on the impeller to shaft helps

[@TheAfterWorkGarage]

Thanks for the tip, and yes this one was far harder to slide on than I've ever dealt with before, so I feel like the more lubrication the better haha.

[@eustolioesquivel9327]

I have the same motor and getting no spark can u help

[@TheAfterWorkGarage]

I would check the usual, spark plugs, spark plug leads, coils/magnetos, and wiring. You'll have to pull the flywheel to check the parts on the stator. I actually ended up pulling the powerhead from this motor to replace the reed valves (should be coming soon), and I'll post that video soon with some info on pulling the flywheel. Good luck, and if you figure out the issue please share!

[@eustolioesquivel9327]

@@TheAfterWorkGarage ok will do it's funny cause I had the motor running fine and I pulled the flywheel off to put a new trigger and put everything back and no spark but before it would fire right up

[@TheAfterWorkGarage]

@@eustolioesquivel9327 When things like that happen to me, the first thing I do is go back and check to see if I reconnected everything (including the little ground straps they sneak on nuts holding other things on). In addition, make sure you don't have the system grounded out anywhere it shouldn't be (like the kill switch wiring) as that will prematurely route the electrical impulse back to the block and bypass the spark.

[@eustolioesquivel9327]

@@TheAfterWorkGarage thank you I got it it was the trigger replaced it and now runs fine

[@TheAfterWorkGarage]

@@eustolioesquivel9327 Awesome, good work and thanks for the update. I hope you enjoy your motor!

[@tonyferri1745]

I know how to lock the motor in the up position I don't know where the unlock is to raise it up

[@TheAfterWorkGarage]

There should be two hooks under the motor that lock it down when it is in reverse. You can try shifting the motor in drive, and a cam should push a rod up which releases these hooks. If this isn't working (or has been lost with time and age) you can reach up underneath where the motor attaches to the bracket, and pull these hooks down manually with your hand or some pliers. They are spring loaded and hook onto a pin in the bracket, so you may have to do some jiggling, but they do come up.

[@Btsoerheim]

Great video, love the shoes 👍

[@TheAfterWorkGarage]

Haha thank you. I'm sort of a one pair of shoes at a time guy.

[@filipvonthelemann4889]

Just bought the same engine! And same problem! It got hott...

[@TheAfterWorkGarage]

Good luck going through it. Many times you'll get lucky and it'll still run well, even it it looks a little less than perfect from an overheat. Just make sure everything is working with the cooling system so it doesn't happen again. Older 2 strokes tend to be pretty bulletproof, so there's a good chance you can save it.

[@filipvonthelemann4889]

@@TheAfterWorkGarage awesoume! my friend removed the impeller today and it was shredded so we might be luckey :P

[@TheAfterWorkGarage]

@@filipvonthelemann4889 Awesome, fingers crossed. Just make sure to check for rubber pieces that may be stuck in the cooling passages.