Car Fix DIY Videos

See how to change the thermostat in your outboard in this video from Boats.net!

We’re working with a Mercury Tracker 40 2-Stroke here, and you’ll need three parts:

Mercury 40 replacement thermostat: https://www.boats.net/product/mercury/895338?utm_source=youtube&utm_medium=video&utm_campaign=description_atf_BDN

Diaphragm: https://www.boats.net/product/mercury/812887?utm_source=youtube&utm_medium=video&utm_campaign=description_atf_BDN

Gasket: https://www.boats.net/product/mercury/8128672?utm_source=youtube&utm_medium=video&utm_campaign=description_atf_BDN

We’re rebuilding a Mercury 40 2-stroke outboard, so we’re removing the thermostat from one motor and moving a couple of pieces over to a rebuilt motor. However, the process is the same if you’re just removing and replacing the thermostat on your motor.

We’ll start by removing the thermostat cover basically so we can get to a spring, the diaphragm washer, and the end cap that holds the diaphragm in place. We’ll remove the old diaphragm and get a new one in place, and then we’ll position the spring and a new thermostat on the cover.

Then, we’ll take the whole assembly and bolt it in place on the new engine block.

Find the thermostat in the top right of this diagram: https://www.boats.net/catalog/mercury/outboard/40hp/40hp-0g760300-thru-0t979999/cylinder-block?utm_source=youtube&utm_medium=video&utm_campaign=description_btf_BDN

VIDEO HIGHLIGHTS:
Removing old thermostat – 0:54
Replacing diaphragm – 2:00
Installing thermostat – 2:30

Find Mercury outboard parts here:
https://www.boats.net/catalog/mercury/outboard?utm_source=youtube&utm_medium=video&utm_campaign=description_btf_BDN

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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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