Mercury 2 Stroke Fuel Pump Rebuild | Mercury 40 HP 2 Stroke Fuel Pump | Mercury Tracker | Boats.net

Get a Mercury 40 HP 2 stroke fuel pump rebuild kit here: www.boats.net/product/mercury...
A note here: this engine remained largely the same from 1988 through 2008. While John mentions a 2004, these instructions should work for a 2002 model as well.
See how to do a Mercury Tracker 40 HP fuel pump rebuild in this video from Boats.net! Only one part number here, and you’ll see it above. This has the gaskets, the diaphragm, springs, and the hardware you need.
We’ve done a lot of work on this unit, so a lot of stuff is removed. However, as you’ll see, removing the fuel pump is a simple job and doesn’t require a lot of work.
With the fuel pump off, we’ll make some marks that will make reassembly easier and then dive into it. This is a newer unit, so it has nylon check valves that are the same as the ones in the kit. They basically snap in and out with small retaining pins. From there, we’ll start re-stacking the layers of the fuel pump, adding in the new gaskets and diaphragm.
Find Mercury Tracker 40 diagrams here: www.boats.net/catalog/mercury...
VIDEO HIGHLIGHTS:
Removing the fuel pump - 1:00
Disassembling the fuel pump - 1:50
Removing and replacing check valves - 3:30
Reassembling the fuel pump - 5:30
Replacing the fuel pump on the engine - 7:00
Find parts for your Mercury outboard 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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[@medicinaljourney5505]

Great video. Very informative and clear. KZbin needs more content like this.

[@dylanbaldwin3769]

Keep these coming! I’m rebuilding a similar engine right now so these videos have been helpful. The 40 is looking good.

[@lelandwilliams2676]

Thank you. I am currently working on a 2007 50 hp EFI 4 stroke. It ran for 20 minutes, then VST output pressure dropped to 2psi and jumped back up to 43psi. It did it two more times them shut off.

[@bouldernelsonbigfoot]

great vid

[@martinpescador1289]

Ótimo vídeo parabéns (Brazil)

[@lelandwilliams2676]

I also ordered a new low pressure pump as well

[@dupontpascal1526]

merci a vous

[@lelandwilliams2676]

The pump in the VST looks good, no real dirt, so I'm going to replace the pump

[@ethanlocke6331]

It has triangles to line up and when you were stacking it to reassemble you started upside down. I knew immediately that spring was gonna give you troubles.

[@bbreede1]

I could not get the center pins to push in at all for the check valves. It wouldn't go in at all and broke off. I couldn't really get the other one to move either before I even insert it. I was just checking it after I broke the first one and it wouldn't move down before I even put in the pump.

[@robnall3483]

I have a fuel pump off of a 1995 two-stroke 60 hp mercury order a new kit for the pump. It came with two clear nylon check valves and two rubber ones, the original carburetor but I took it off. Did not have the rubber in it can I still use it And combination. Thanks.

[@brunocauin]

Is there a way to upgrade these to an electric pump? I rebuilt mine, installed all new lines and filter but can't seem to get enough fuel pressure...

[@user-bv7so8nw8m]

Good morning sir.... Can you to tell me where to buy those replacement kit of fuel pump.. mine is 75hp mercury looks the same from what you have on your demo clip... Please

[@danielguerra626]

Can you do a video on a Mercury V6 carb rebuild?

[@TERRYSMITH-vu6er]

I HAVE A 50 HP MERCURY 2 STROKE THAT ALL OF SUDDEN LOCKED UP I PUT A NEW STARTER/SOLINOID BEFORE THEN IT WAS TURNING OVER GOOD ANY IDEAS

[@daveskura]

great video

[@NinoSpinner]

Vorrei montare una pompa su un fuoribordo Mercury 3.5 su cui è presente solo il serbatoio incorporato Vorrei dunque installare una pompa benzina da collegare ad un serbatoio esterno Che tipo di pompa posso montare? C'è qualche cosa da sapere prima di acquistarne una adeguata? Grazie

[@ayhankucukozer1478]

Mercury 50 hp marine engine fuel is not coming to the spark plugs. I am thinking. injectors are solid. ecu is solid. When you add a few drops of gasoline into the cylinders, the engine starts and then stops. Cylinder pressure is very good. When you press the starter to start the engine, oily gasoline comes out of the exhaust. Can you help me? Also, there are syringes inside the log. I don't understand what they do. Greetings from Turkey.

[@tfrantastic]

Any reason to rebuild this if there is no issue?

[@upinstylesalon]

I have it all done. Took it off last year and now I have forgotten where the lines from it go :( I have pictures of mine.

[@harrytselios4228]

Wondering why newer motors have more engine block failures than the older engines?

[@garneroutlaw1]

Great video, but the manual says to break it off prior to pushing the pin in, not after seating the pin. It seated as intended in this video. There is not supposed to be anything to break or snip off.

[@bigl2thad2005]

Your suppose to line up the triangles on the fuel pump housing and gaskets together. No need to mark it. You gave it flipped on one end sir.

[@Shoot_and_Scoot]

That’s cool, if you guys would send me my fuel pump rebuild kit I ordered two weeks ago I could rebuild my fuel pump too….