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: https://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: https://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:
https://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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